PHOTOVOLTAIC MODULES FOR COMMERCIAL ROOFING

A roll, comprising: a laminate, comprising: a plurality of solar cells, wherein the plurality of solar cells comprises: a first solar cell, a second solar cell, and a third solar cell, wherein the first solar cell and the second solar cell are separated in a first direction by a first distance, wherein the second solar cell and the third solar cell are separated in the first direction by the first distance, and wherein each of the first, second, and third solar cells comprises: a width in the first direction, and a length in a second direction, wherein the second direction is perpendicular to the first direction; a first encapsulant, wherein the first encapsulant encapsulates the plurality of solar cells, and wherein the first encapsulant includes a first surface and a second surface opposite the first surface; a frontsheet, wherein the frontsheet includes a first surface and a second surface opposite the first surface of the frontsheet, wherein the second surface of the frontsheet is adjacent the first surface of the first encapsulant; and a backsheet, wherein the backsheet includes a first surface and a second surface opposite the first surface of the backsheet, wherein the first surface of the backsheet is adjacent the second surface of the first encapsulant, and wherein the widths of the first, second, and third solar cells, and the first and second distances are sized to permit at least a portion of the first surface of the frontsheet to be juxtaposed circumferentially with at least a portion of the second surface of the backsheet.

FIELD OF THE INVENTION

The present invention relates to photovoltaic modules, and, more particularly, photovoltaic modules for commercial roofing.

BACKGROUND

Photovoltaic systems having solar panels are commonly installed on roofing of structures. What is needed are photovoltaic modules that are configured to be installed on commercial roofing systems.

SUMMARY

In some embodiments, a system includes a roof deck, wherein the roof deck includes a slope of 0.25 inch to 3 inches per foot, wherein the roof deck includes a roofing membrane, and wherein the roofing membrane is composed of a first material; and at least one photovoltaic module installed on the roof deck, the photovoltaic module including at least one solar cell an encapsulant encapsulating the at least one solar cell, wherein the encapsulant includes a first surface and a second surface opposite the first surface, a frontsheet juxtaposed with the first surface of the encapsulant, and a backsheet juxtaposed with the second surface of the encapsulant, wherein the backsheet includes a head flap located at a first end of the backsheet, and a bottom flap located at a second end of the backsheet opposite the first end, wherein the backsheet is composed of the first material, wherein at least a first portion of the head flap is attached to the roofing membrane, and wherein at least a second portion of the bottom flap is attached to the roofing membrane.

In some embodiments, the first material is composed of a polymeric material. In some embodiments, the first material is composed of thermoplastic polyolefin (TPO). In some embodiments, the head flap and the bottom flap are attached to the roofing membrane by an adhesive. In some embodiments, the head flap and the bottom flap are attached to the roofing membrane by thermal bonding. In some embodiments, the head flap and the bottom flap are attached to the roofing membrane by ultrasonic welding. In some embodiments, the backsheet includes a first side flap located at a first side of the photovoltaic module and a second side flap located at a second side of the photovoltaic module opposite the first side, wherein at least a third portion of the first side flap is attached to the roofing membrane and at least a fourth portion of the second side flap is attached to the roofing membrane.

In some embodiments, the backsheet includes a first surface and a second surface opposite the first surface of the backsheet, and wherein the first surface of the backsheet is juxtaposed with the second surface of the encapsulant. In some embodiments, the second surface of the second portion of the bottom flap is attached to the roofing membrane. In some embodiments, the second surface of the first portion of the head flap is attached to the roofing membrane. In some embodiments, the first surface of the first portion of the head flap is attached to the roofing membrane. In some embodiments, the head flap includes a free end, wherein the free end of the head flap is folded relative to itself and forms a rounded end. In some embodiments, the rounded end includes a first portion juxtaposed with the roofing membrane and a second portion relative to the roofing membrane, wherein the second portion of the rounded end is elevated relative to the roofing membrane. In some embodiments, the first surface of at least the first portion of the rounded end is attached to the roofing membrane. In some embodiments, the second portion of the rounded end is sloped 0.1 degrees to 15 degrees.

In some embodiments, the system further includes at least one support member located intermediate a corresponding one of the at least one photovoltaic module and the roofing membrane, and wherein a portion of the at least one photovoltaic module is elevated relative to the roofing membrane. In some embodiments, the at least one solar cell includes a first plurality of solar cells arranged in a first array, and a second plurality of solar cells arranged in a second array, wherein the at least one photovoltaic module includes a first section, a second section, and a region located intermediate the first section and the second section, wherein the first array is located within the first section, wherein the second array is located within the second section, wherein the at least one support member is juxtaposed with the region.

In some embodiments, the at least one support member includes a rod. In some embodiments, the at least one support member is composed of thermoplastic polyolefin (TPO). In some embodiments, each of the first section and the second section is elevated relative to the roofing membrane, wherein the first section is sloped 0.1 degrees to 15 degrees, and wherein the second section is sloped 0.1 degrees to 15 degrees.

In some embodiments, the present invention provides a roll that comprises a laminate, which comprises: a plurality of solar cells, wherein the plurality of solar cells comprises a first solar cell, a second solar cell, and a third solar cell, wherein the first solar cell and the second solar cell are separated in a first direction by a first distance, wherein the second solar cell and the third solar cell are separated in the first direction by the first distance, and wherein each of the first, second, and third solar cells comprises: a width in the first direction, and a length in a second direction, wherein the second direction is perpendicular to the first direction; a first encapsulant, wherein the first encapsulant encapsulates the plurality of solar cells, and wherein the first encapsulant includes a first surface and a second surface opposite the first surface; a frontsheet, wherein the frontsheet includes a first surface and a second surface opposite the first surface of the frontsheet, wherein the second surface of the frontsheet is adjacent the first surface of the first encapsulant; and a backsheet, wherein the backsheet includes a first surface and a second surface opposite the first surface of the backsheet, wherein the first surface of the backsheet is adjacent the second surface of the first encapsulant, and wherein the widths of the first, second, and third solar cells, and the first and second distances are sized to permit at least a portion of the first surface of the frontsheet to be juxtaposed circumferentially with at least a portion of the second surface of the backsheet.

In some embodiments, the backsheet comprises a thermoplastic polyolefin.

In some embodiments, the at least a portion of the frontsheet contacts the at least a portion of the backsheet.

In some embodiments, the roll further comprises a longitudinal axis, wherein the first direction is perpendicular to the longitudinal axis, and wherein the second direction is parallel to the longitudinal axis.

In some embodiments, the backsheet contacts the second surface of the first encapsulant.

In some embodiments, the frontsheet contacts the first surface of the first encapsulant.

In some embodiments, the frontsheet comprises a transparent material.

In some embodiments, the transparent material comprises at least one of polymer and glass.

In some embodiments, the laminate further comprises: a support layer, wherein the support layer is adjacent the second surface of the first encapsulant; and a second encapsulant, wherein the second encapsulant is between the support layer and the backsheet.

In some embodiments, each of the first and second encapsulants comprises a same material.

In some embodiments, the present invention provides a method, comprising: obtaining a roll, the roll comprising: a laminate, comprising: a plurality of solar cells, wherein the plurality of solar cells comprises a first solar cell, a second solar cell, and a third solar cell, wherein the first solar cell and the second solar cell are separated in a first direction by a first distance, wherein the second solar cell and the third solar cell are separated in the first direction by the first distance, and wherein each of the first, second, and third solar cells comprises: a width in the first direction, and a length in a second direction, wherein the second direction is perpendicular to the first direction; a first encapsulant, wherein the first encapsulant encapsulates the plurality of solar cells, and wherein the first encapsulant includes a first surface and a second surface opposite the first surface; a frontsheet, wherein the frontsheet includes a first surface and a second surface opposite the first surface of the frontsheet, wherein the second surface of the frontsheet is adjacent the first surface of the first encapsulant; and a backsheet, wherein the backsheet includes a first surface and a second surface opposite the first surface of the backsheet, wherein the first surface of the backsheet is adjacent the second surface of the first encapsulant, and wherein the widths of the first, second, and third solar cells, and the first and second distances are sized to permit at least a portion of the first surface of the frontsheet to be juxtaposed circumferentially with at least a portion of the second surface of the backsheet; and unrolling the roll so as to install the laminate on a roof deck, wherein the second surface of the backsheet is juxtaposed with a surface of the roof deck.

In some embodiments, the unrolling the roll comprises unrolling the roll so as to install the laminate directly on the roof deck without any intervening member between the laminate and the roof deck.

In some embodiments, the method further comprises welding the laminate to the roof deck.

In some embodiments, the roof deck is a flat roof deck.

In some embodiments, the roof deck is a sloped roof deck.

DETAILED DESCRIPTION

The present invention will be further explained with reference to the attached drawings, wherein like structures are referred to by like numerals throughout the several views. The drawings shown are not necessarily to scale, with emphasis instead generally being placed upon illustrating the principles of the present invention. Further, some features may be exaggerated to show details of particular components.

The figures constitute a part of this specification and include illustrative embodiments of the present invention and illustrate various objects and features thereof. Further, the figures are not necessarily to scale, some features may be exaggerated to show details of particular components. In addition, any measurements, specifications and the like shown in the figures are intended to be illustrative, and not restrictive. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a representative basis for teaching one skilled in the art to variously employ the present invention.

Among those benefits and improvements that have been disclosed, other objects and advantages of this invention will become apparent from the following description taken in conjunction with the accompanying figures. Detailed embodiments of the present invention are disclosed herein; however, it is to be understood that the disclosed embodiments are merely illustrative of the invention that may be embodied in various forms. In addition, each of the examples given in connection with the various embodiments of the invention which are intended to be illustrative, and not restrictive.

Referring toFIGS.1A and1B, in some embodiments, a photovoltaic module10includes at least one solar cell12, an encapsulant14encapsulating the at least one solar cell12, and a frontsheet16juxtaposed with the encapsulant14. In some embodiments, the elements of the photovoltaic module10may be laminated with each other, such that the photovoltaic module10is in the form of a laminate. In some embodiments, the frontsheet16is juxtaposed with a first surface of the encapsulant14. As used herein, the terms “encapsulating” and “encapsulates” mean to partially or fully envelope or enclose, and with respect to certain embodiments of the photovoltaic module10, the at least one solar cell12is fully enveloped by or enclosed within the encapsulant14, or partially enveloped by or enclosed within the encapsulant14. In some embodiments, the encapsulant14encapsulates 50% to 99.9% of an exterior surface area of the at least one solar cell12. In another embodiment, the encapsulant14encapsulates 55% to 99.9% of an exterior surface area of the at least one solar cell12. In another embodiment, the encapsulant14encapsulates 60% to 99.9% of an exterior surface area of the at least one solar cell12. In another embodiment, the encapsulant14encapsulates 65% to 99.9% of an exterior surface area of the at least one solar cell12. In another embodiment, the encapsulant14encapsulates 70% to 99.9% of an exterior surface area of the at least one solar cell12. In another embodiment, the encapsulant14encapsulates 75% to 99.9% of an exterior surface area of the at least one solar cell12. In another embodiment, the encapsulant14encapsulates 80% to 99.9% of an exterior surface area of the at least one solar cell12. In another embodiment, the encapsulant14encapsulates 85% to 99.9% of an exterior surface area of the at least one solar cell12. In another embodiment, the encapsulant14encapsulates 90% to 99.9% of an exterior surface area of the at least one solar cell12. In another embodiment, the encapsulant14encapsulates 95% to 99.9% of an exterior surface area of the at least one solar cell12.

In another embodiment, the encapsulant14encapsulates 50% to 95% of an exterior surface area of the at least one solar cell12. In another embodiment, the encapsulant14encapsulates 55% to 95% of an exterior surface area of the at least one solar cell12. In another embodiment, the encapsulant14encapsulates 60% to 95% of an exterior surface area of the at least one solar cell12. In another embodiment, the encapsulant14encapsulates 65% to 95% of an exterior surface area of the at least one solar cell12. In another embodiment, the encapsulant14encapsulates 70% to 95% of an exterior surface area of the at least one solar cell12. In another embodiment, the encapsulant14encapsulates 75% to 95% of an exterior surface area of the at least one solar cell12. In another embodiment, the encapsulant14encapsulates 80% to 95% of an exterior surface area of the at least one solar cell12. In another embodiment, the encapsulant14encapsulates 85% to 95% of an exterior surface area of the at least one solar cell12. In another embodiment, the encapsulant14encapsulates 90% to 95% of an exterior surface area of the at least one solar cell12.

In another embodiment, the encapsulant14encapsulates 50% to 90% of an exterior surface area of the at least one solar cell12. In another embodiment, the encapsulant14encapsulates 55% to 90% of an exterior surface area of the at least one solar cell12. In another embodiment, the encapsulant14encapsulates 60% to 90% of an exterior surface area of the at least one solar cell12. In another embodiment, the encapsulant14encapsulates 65% to 90% of an exterior surface area of the at least one solar cell12. In another embodiment, the encapsulant14encapsulates 70% to 90% of an exterior surface area of the at least one solar cell12. In another embodiment, the encapsulant14encapsulates 75% to 90% of an exterior surface area of the at least one solar cell12. In another embodiment, the encapsulant14encapsulates 80% to 90% of an exterior surface area of the at least one solar cell12. In another embodiment, the encapsulant14encapsulates 85% to 90% of an exterior surface area of the at least one solar cell12.

In another embodiment, the encapsulant14encapsulates 50% to 85% of an exterior surface area of the at least one solar cell12. In another embodiment, the encapsulant14encapsulates 55% to 85% of an exterior surface area of the at least one solar cell12. In another embodiment, the encapsulant14encapsulates 60% to 85% of an exterior surface area of the at least one solar cell12. In another embodiment, the encapsulant14encapsulates 65% to 85% of an exterior surface area of the at least one solar cell12. In another embodiment, the encapsulant14encapsulates 70% to 85% of an exterior surface area of the at least one solar cell12. In another embodiment, the encapsulant14encapsulates 75% to 85% of an exterior surface area of the at least one solar cell12. In another embodiment, the encapsulant14encapsulates 80% to 85% of an exterior surface area of the at least one solar cell12.

In another embodiment, the encapsulant14encapsulates 50% to 80% of an exterior surface area of the at least one solar cell12. In another embodiment, the encapsulant14encapsulates 55% to 80% of an exterior surface area of the at least one solar cell12. In another embodiment, the encapsulant14encapsulates 60% to 80% of an exterior surface area of the at least one solar cell12. In another embodiment, the encapsulant14encapsulates 65% to 80% of an exterior surface area of the at least one solar cell12. In another embodiment, the encapsulant14encapsulates 70% to 80% of an exterior surface area of the at least one solar cell12. In another embodiment, the encapsulant14encapsulates 75% to 80% of an exterior surface area of the at least one solar cell12.

In another embodiment, the encapsulant14encapsulates 50% to 75% of an exterior surface area of the at least one solar cell12. In another embodiment, the encapsulant14encapsulates 55% to 75% of an exterior surface area of the at least one solar cell12. In another embodiment, the encapsulant14encapsulates 60% to 75% of an exterior surface area of the at least one solar cell12. In another embodiment, the encapsulant14encapsulates 65% to 75% of an exterior surface area of the at least one solar cell12. In another embodiment, the encapsulant14encapsulates 70% to 75% of an exterior surface area of the at least one solar cell12.

In another embodiment, the encapsulant14encapsulates 50% to 70% of an exterior surface area of the at least one solar cell12. In another embodiment, the encapsulant14encapsulates 55% to 70% of an exterior surface area of the at least one solar cell12. In another embodiment, the encapsulant14encapsulates 60% to 70% of an exterior surface area of the at least one solar cell12. In another embodiment, the encapsulant14encapsulates 65% to 70% of an exterior surface area of the at least one solar cell12.

In another embodiment, the encapsulant14encapsulates 50% to 65% of an exterior surface area of the at least one solar cell12. In another embodiment, the encapsulant14encapsulates 55% to 65% of an exterior surface area of the at least one solar cell12. In another embodiment, the encapsulant14encapsulates 60% to 65% of an exterior surface area of the at least one solar cell12. In another embodiment, the encapsulant14encapsulates 50% to 60% of an exterior surface area of the at least one solar cell12. In another embodiment, the encapsulant14encapsulates 55% to 60% of an exterior surface area of the at least one solar cell12. In another embodiment, the encapsulant14encapsulates 55% to 60% of an exterior surface area of the at least one solar cell12.

In some embodiments, the encapsulant14encapsulates 50% of an exterior surface area of the at least one solar cell12. In another embodiment, the encapsulant14encapsulates 55% of the exterior surface area of the at least one solar cell12. In another embodiment, the encapsulant14encapsulates 60% of the exterior surface area of the at least one solar cell12. In another embodiment, the encapsulant14encapsulates 65% of the exterior surface area of the at least one solar cell12. In another embodiment, the encapsulant14encapsulates 70% of the exterior surface area of the at least one solar cell12. In another embodiment, the encapsulant14encapsulates 75% of the exterior surface area of the at least one solar cell12. In another embodiment, the encapsulant14encapsulates 80% of the exterior surface area of the at least one solar cell12. In another embodiment, the encapsulant14encapsulates 85% of the exterior surface area of the at least one solar cell12. In another embodiment, the encapsulant14encapsulates 90% of the exterior surface area of the at least one solar cell12. In another embodiment, the encapsulant14encapsulates 95% of the exterior surface area of the at least one solar cell12. In another embodiment, the encapsulant14encapsulates 100% of the exterior surface area of the at least one solar cell12.

In some embodiments, the encapsulant14has a thickness of 0.5 mm to 4 mm. In another embodiment, the encapsulant14has a thickness of 0.5 mm to 3.5 mm. In another embodiment, the encapsulant14has a thickness of 0.5 mm to 3 mm. In another embodiment, the encapsulant14has a thickness of 0.5 mm to 2.5 mm. In another embodiment, the encapsulant14has a thickness of 0.5 mm to 2 mm. In another embodiment, the encapsulant14has a thickness of 0.5 mm to 1.5 mm. In another embodiment, the encapsulant14has a thickness of 0.5 mm to 1 mm.

In some embodiments, the encapsulant14has a thickness of 1 mm to 4 mm. In another embodiment, the encapsulant14has a thickness of 1 mm to 3.5 mm. In another embodiment, the encapsulant14has a thickness of 1 mm to 3 mm. In another embodiment, the encapsulant14has a thickness of 1 mm to 2.5 mm. In another embodiment, the encapsulant14has a thickness of 1 mm to 2 mm. In another embodiment, the encapsulant14has a thickness of 1 mm to 1.5 mm. In some embodiments, the encapsulant14has a thickness of 1.5 mm to 4 mm. In another embodiment, the encapsulant14has a thickness of 1.5 mm to 3.5 mm. In another embodiment, the encapsulant14has a thickness of 1.5 mm to 3 mm. In another embodiment, the encapsulant14has a thickness of 1.5 mm to 2.5 mm. In another embodiment, the encapsulant14has a thickness of 1.5 mm to 2 mm.

In some embodiments, the encapsulant14has a thickness of 2 mm to 4 mm. In another embodiment, the encapsulant14has a thickness of 2 mm to 3.5 mm. In another embodiment, the encapsulant14has a thickness of 2 mm to 3 mm. In another embodiment, the encapsulant14has a thickness of 2 mm to 2.5 mm. In some embodiments, the encapsulant14has a thickness of 2.5 mm to 4 mm. In another embodiment, the encapsulant14has a thickness of 2.5 mm to 3.5 mm. In another embodiment, the encapsulant14has a thickness of 2.5 mm to 3 mm. In some embodiments, the encapsulant14has a thickness of 3 mm to 4 mm. In another embodiment, the encapsulant14has a thickness of 3 mm to 3.5 mm. In some embodiments, the encapsulant14has a thickness of 3.5 mm to 4 mm.

In some embodiments, the encapsulant14has a thickness of 0.5 mm. In some embodiments, the encapsulant14has a thickness of 0.6 mm. In some embodiments, the encapsulant14has a thickness of 0.7 mm. In some embodiments, the encapsulant14has a thickness of 0.8 mm. In some embodiments, the encapsulant14has a thickness of 0.9 mm. In some embodiments, the encapsulant14has a thickness of 1 mm. In some embodiments, the encapsulant14has a thickness of 1.5 mm. In some embodiments, the encapsulant14has a thickness of 2 mm. In some embodiments, the encapsulant14has a thickness of 2.5 mm. In some embodiments, the encapsulant14has a thickness of 3 mm. In some embodiments, the encapsulant14has a thickness of 3.5 mm. In some embodiments, the encapsulant14has a thickness of 4 mm.

In some embodiments, a first layer14aof the encapsulant14has a thickness of 0.2 mm to 2 mm. In some embodiments, the first layer14aof the encapsulant14has a thickness of 0.2 mm to 1.5 mm. In some embodiments, the first layer14aof the encapsulant14has a thickness of 0.2 mm to 1 mm. In some embodiments, the first layer14aof the encapsulant14has a thickness of 0.2 mm to 0.6 mm. In some embodiments, the first layer14aof the encapsulant14has a thickness of 0.2 mm to 0.5 mm. In some embodiments, the first layer14aof the encapsulant14has a thickness of 0.5 mm to 2 mm. In some embodiments, the first layer14aof the encapsulant14has a thickness of 0.5 mm to 1.5 mm. In some embodiments, the first layer14aof the encapsulant14has a thickness of 0.5 mm to 1 mm. In some embodiments, the first layer14aof the encapsulant14has a thickness of 1 mm to 2 mm. In some embodiments, the first layer14aof the encapsulant14has a thickness of 1 mm to 1.5 mm. In some embodiments, the first layer14aof the encapsulant14has a thickness of 1.5 mm to 2 mm.

In some embodiments, the first layer14aof the encapsulant14has a thickness of 0.2 mm. In some embodiments, the first layer14aof the encapsulant14has a thickness of 0.3 mm. In some embodiments, the first layer14aof the encapsulant14has a thickness of 0.4 mm. In some embodiments, the first layer14aof the encapsulant14has a thickness of 0.45 mm. In some embodiments, the first layer14aof the encapsulant14has a thickness of 0.5 mm. In some embodiments, the first layer14aof the encapsulant14has a thickness of 0.6 mm. In some embodiments, the first layer14aof the encapsulant14has a thickness of 1 mm. In some embodiments, the first layer14aof the encapsulant14has a thickness of 1.5 mm. In some embodiments, the first layer14aof the encapsulant14has a thickness of 2 mm. In some embodiments, the first layer14aof the encapsulant14has a thickness of 2.5 mm. In some embodiments, the first layer14aof the encapsulant14has a thickness of 3 mm. In some embodiments, the first layer14aof the encapsulant14has a thickness of 3.5 mm. In some embodiments, the first layer14aof the encapsulant14has a thickness of 4 mm.

In some embodiments, a second layer14bof the encapsulant14has a thickness of 0.2 mm to 2 mm. In some embodiments, the second layer14bof the encapsulant14has a thickness of 0.2 mm to 1.5 mm. In some embodiments, the second layer14bof the encapsulant14has a thickness of 0.2 mm to 1 mm. In some embodiments, the second layer14bof the encapsulant14has a thickness of 0.2 mm to 0.5 mm. In some embodiments, the second layer14bof the encapsulant14has a thickness of 0.5 mm to 2 mm. In some embodiments, the second layer14bof the encapsulant14has a thickness of 0.5 mm to 1.5 mm. In some embodiments, the second layer14bof the encapsulant14has a thickness of 0.5 mm to 1 mm. In some embodiments, the second layer14bof the encapsulant14has a thickness of 1 mm to 2 mm. In some embodiments, the second layer14bof the encapsulant14has a thickness of 1 mm to 1.5 mm. In some embodiments, the second layer14bof the encapsulant14has a thickness of 1.5 mm to 2 mm.

In some embodiments, the second layer14bof the encapsulant14has a thickness of 0.2 mm. In some embodiments, the second layer14bof the encapsulant14has a thickness of 0.3 mm. In some embodiments, the second layer14bof the encapsulant14has a thickness of 0.4 mm. In some embodiments, the second layer14bof the encapsulant14has a thickness of 0.45 mm. In some embodiments, the second layer14bof the encapsulant14has a thickness of 0.5 mm. In some embodiments, the second layer14bof the encapsulant14has a thickness of 1 mm. In some embodiments, the second layer14bof the encapsulant14has a thickness of 1.5 mm. In some embodiments, the second layer14bof the encapsulant14has a thickness of 2 mm. In some embodiments, the second layer14bof the encapsulant14has a thickness of 2.5 mm. In some embodiments, the second layer14bof the encapsulant14has a thickness of 3 mm. In some embodiments, the second layer14bof the encapsulant14has a thickness of 3.5 mm. In some embodiments, the second layer14bof the encapsulant14has a thickness of 4 mm.

In some embodiments, the thickness of the first layer14ais equal to the thickness of the second layer14b. In another embodiment, the thickness of the first layer14ais different from the thickness of the second layer14b.

In some embodiments, the encapsulant14may be made from polyolefins, ethyl vinyl acetates, ionomers, silicones, poly vinyl butyral, epoxies, polyurethanes, or combinations/hybrids thereof. In some embodiments, the encapsulant14is made from thermosetting polyolefin.

In some embodiments, the photovoltaic module10includes a first end18, a second end20opposite the first end18, a first surface19extending from the first end18to the second end20, and a second surface21opposite the first surface19and extending from the first end18to the second end20. In some embodiments, the first surface19is an upper, sun facing-side surface of the photovoltaic module10, and the second surface21is a lower surface configured to face a roof deck on which the photovoltaic module10is installed on the roof deck.

In some embodiments, the at least one solar cell12includes a plurality of the solar cells12. In some embodiments, the plurality of solar cells12includes two solar cells. In some embodiments, the plurality of solar cells12includes three solar cells. In some embodiments, the plurality of solar cells12includes four solar cells. In some embodiments, the plurality of solar cells12includes five solar cells. In some embodiments, the plurality of solar cells12includes six solar cells. In some embodiments, the plurality of solar cells12includes seven solar cells. In some embodiments, the plurality of solar cells12includes eight solar cells. In some embodiments, the plurality of solar cells12includes nine solar cells. In some embodiments, the plurality of solar cells12includes ten solar cells. In some embodiments, the plurality of solar cells12includes eleven solar cells. In some embodiments, the plurality of solar cells12includes twelve solar cells. In some embodiments, the plurality of solar cells12includes thirteen solar cells. In some embodiments, the plurality of solar cells12includes fourteen solar cells. In some embodiments, the plurality of solar cells12includes fifteen solar cells. In some embodiments, the plurality of solar cells12includes sixteen solar cells. In some embodiments, the plurality of solar cells12includes more than sixteen solar cells.

In some embodiments, the plurality of solar cells12is arranged in one row (i.e., one reveal). In another embodiment, the plurality of solar cells12is arranged in two rows (i.e., two reveals). In another embodiment, the plurality of solar cells12is arranged in three rows (i.e., three reveals). In another embodiment, the plurality of solar cells12is arranged in four rows (i.e., four reveals). In another embodiment, the plurality of solar cells12is arranged in five rows (i.e., five reveals). In another embodiment, the plurality of solar cells12is arranged in six rows (i.e., six reveals). In other embodiments, the plurality of solar cells12is arranged in more than six rows.

In some embodiments, the frontsheet16includes a glass layer22and a polymer layer24attached to a first surface of the glass layer22. In some embodiments, the frontsheet16is juxtaposed with the first layer14aof the encapsulant14. In some embodiments, each of the encapsulant14, the glass layer22, and the polymer layer24is transparent. In some embodiments, the polymer layer24is attached to the glass layer22by an first adhesive layer26. In some embodiments, the first adhesive layer26may include polyvinyl butyrate, acrylic, silicone, or polycarbonate. In another embodiment, the first adhesive layer26may include pressure sensitive adhesives. In another embodiment, the polymer layer24is attached to the glass layer22by thermal bonding. In another embodiment, the frontsheet16includes at least one of the glass layer22or the polymer layer24. In some embodiments, the first adhesive layer26is transparent. As used herein, the term “transparent” means having a solar weighted transmittance of 80% or greater, and with respect to certain embodiments of the photovoltaic module10, a transparent layer of the photovoltaic module has a solar weighted transmittance of 80% or greater. In another embodiment, the frontsheet16does not include the glass layer22.

In some embodiments, the glass layer22has a thickness of 1 mm to 4 mm. In some embodiments, the glass layer22has a thickness of 1 mm to 3.5 mm. In some embodiments, the glass layer22has a thickness of 1 mm to 3 mm. In some embodiments, the glass layer22has a thickness of 1 mm to 2.5 mm. In some embodiments, the glass layer22has a thickness of 1 mm to 2 mm. In some embodiments, the glass layer22has a thickness of 1 mm to 1.5 mm. In some embodiments, the glass layer22has a thickness of 1.5 mm to 4 mm. In some embodiments, the glass layer22has a thickness of 1.5 mm to 3.5 mm. In some embodiments, the glass layer22has a thickness of 1.5 mm to 3 mm. In some embodiments, the glass layer22has a thickness of 1 mm to 2.5 mm. In some embodiments, the glass layer22has a thickness of 1.5 mm to 2 mm.

In some embodiments, the glass layer22has a thickness of 2 mm to 4 mm. In some embodiments, the glass layer22has a thickness of 2 mm to 3.5 mm. In some embodiments, the glass layer22has a thickness of 2 mm to 3 mm. In some embodiments, the glass layer22has a thickness of 2 mm to 2.5 mm. In some embodiments, the glass layer22has a thickness of 2.5 mm to 4 mm. In some embodiments, the glass layer22has a thickness of 2.5 mm to 3.5 mm. In some embodiments, the glass layer22has a thickness of 2.5 mm to 3 mm. In some embodiments, the glass layer22has a thickness of 3 mm to 4 mm. In some embodiments, the glass layer22has a thickness of 3 mm to 3.5 mm. In some embodiments, the glass layer22has a thickness of 3.5 mm to 4 mm.

In some embodiments, the glass layer22has a thickness of 1 mm. In some embodiments, the glass layer22has a thickness of 1.5 mm. In some embodiments, the glass layer22has a thickness of 2 mm. In some embodiments, the glass layer22has a thickness of 2.5 mm. In some embodiments, the glass layer22has a thickness of 3 mm. In some embodiments, the glass layer22has a thickness of 3.5 mm. In some embodiments, the glass layer22has a thickness of 4 mm.

In some embodiments, the first adhesive layer26has a thickness of 0.2 mm to 2 mm. In some embodiments, the first adhesive layer26has a thickness of 0.2 mm to 1.5 mm. In some embodiments, the first adhesive layer26has a thickness of 0.2 mm to 1 mm. In some embodiments, the first adhesive layer26has a thickness of 0.2 mm to 0.5 mm. In some embodiments, the first adhesive layer26has a thickness of 0.5 mm to 2 mm. In some embodiments, the first adhesive layer26has a thickness of 0.5 mm to 1.5 mm. In some embodiments, the first adhesive layer26has a thickness of 0.5 mm to 1 mm. In some embodiments, the first adhesive layer26has a thickness of 1 mm to 2 mm. In some embodiments, the first adhesive layer26has a thickness of 1 mm to 1.5 mm. In some embodiments, the first adhesive layer26has a thickness of 1.5 mm to 2 mm.

In some embodiments, the first adhesive layer26has a thickness of 0.2 mm. In some embodiments, the first adhesive layer26has a thickness of 0.3 mm. In some embodiments, the first adhesive layer26has a thickness of 0.4 mm. In some embodiments, the first adhesive layer26has a thickness of 0.45 mm. In some embodiments, the first adhesive layer26has a thickness of 0.5 mm. In some embodiments, the first adhesive layer26has a thickness of 1 mm. In some embodiments, the first adhesive layer26has a thickness of 1.5 mm. In some embodiments, the first adhesive layer26has a thickness of 2 mm. In some embodiments, the first adhesive layer26has a thickness of 2.5 mm. In some embodiments, the first adhesive layer26has a thickness of 3 mm. In some embodiments, the first adhesive layer26has a thickness of 3.5 mm. In some embodiments, the first adhesive layer26has a thickness of 4 mm.

In some embodiments, the first adhesive layer26has a thickness of 150 μm to 900 μm. In some embodiments, the first adhesive layer26has a thickness of 150 μm to 850 μm. In some embodiments, the first adhesive layer26has a thickness of 150 μm to 800 μm. In some embodiments, the first adhesive layer26has a thickness of 150 μm to 750 μm. In some embodiments, the first adhesive layer26has a thickness of 150 μm to 700 μm. In some embodiments, the first adhesive layer26has a thickness of 150 μm to 650 μm. In some embodiments, the first adhesive layer26has a thickness of 150 μm to 600 μm. In some embodiments, the first adhesive layer26has a thickness of 150 μm to 550 μm. In some embodiments, the first adhesive layer26has a thickness of 150 μm to 500 μm. In some embodiments, the first adhesive layer26has a thickness of 150 μm to 450 μm. In some embodiments, the first adhesive layer26has a thickness of 150 μm to 400 μm. In some embodiments, the first adhesive layer26has a thickness of 150 μm to 350 μm. In some embodiments, the first adhesive layer26has a thickness of 150 μm to 300 μm. In some embodiments, the first adhesive layer26has a thickness of 150 μm to 250 μm. In some embodiments, the first adhesive layer26has a thickness of 150 μm to 200 μm.

In some embodiments, the first adhesive layer26has a thickness of 200 μm to 900 μm. In some embodiments, the first adhesive layer26has a thickness of 200 μm to 850 μm. In some embodiments, the first adhesive layer26has a thickness of 200 μm to 800 μm. In some embodiments, the first adhesive layer26has a thickness of 200 μm to 750 μm. In some embodiments, the first adhesive layer26has a thickness of 200 μm to 700 μm. In some embodiments, the first adhesive layer26has a thickness of 200 μm to 650 μm. In some embodiments, the first adhesive layer26has a thickness of 200 μm to 600 μm. In some embodiments, the first adhesive layer26has a thickness of 200 μm to 550 μm. In some embodiments, the first adhesive layer26has a thickness of 200 μm to 500 μm. In some embodiments, the first adhesive layer26has a thickness of 200 μm to 450 μm. In some embodiments, the first adhesive layer26has a thickness of 200 μm to 400 μm. In some embodiments, the first adhesive layer26has a thickness of 200 μm to 350 μm. In some embodiments, the first adhesive layer26has a thickness of 200 μm to 300 μm. In some embodiments, the first adhesive layer26has a thickness of 200 μm to 250 μm.

In some embodiments, the first adhesive layer26has a thickness of 250 μm to 900 μm. In some embodiments, the first adhesive layer26has a thickness of 250 μm to 850 μm. In some embodiments, the first adhesive layer26has a thickness of 250 μm to 800 μm. In some embodiments, the first adhesive layer26has a thickness of 250 μm to 750 μm. In some embodiments, the first adhesive layer26has a thickness of 250 μm to 700 μm. In some embodiments, the first adhesive layer26has a thickness of 250 μm to 650 μm. In some embodiments, the first adhesive layer26has a thickness of 250 μm to 600 μm. In some embodiments, the first adhesive layer26has a thickness of 250 μm to 550 μm. In some embodiments, the first adhesive layer26has a thickness of 250 μm to 500 μm. In some embodiments, the first adhesive layer26has a thickness of 250 μm to 450 μm. In some embodiments, the first adhesive layer26has a thickness of 250 μm to 400 μm. In some embodiments, the first adhesive layer26has a thickness of 250 μm to 350 μm. In some embodiments, the first adhesive layer26has a thickness of 250 μm to 300 μm.

In some embodiments, the first adhesive layer26has a thickness of 300 μm to 900 μm. In some embodiments, the first adhesive layer26has a thickness of 300 μm to 850 μm. In some embodiments, the first adhesive layer26has a thickness of 300 μm to 800 μm. In some embodiments, the first adhesive layer26has a thickness of 300 μm to 750 μm. In some embodiments, the first adhesive layer26has a thickness of 300 μm to 700 μm. In some embodiments, the first adhesive layer26has a thickness of 300 μm to 650 μm. In some embodiments, the first adhesive layer26has a thickness of 300 μm to 600 μm. In some embodiments, the first adhesive layer26has a thickness of 300 μm to 550 μm. In some embodiments, the first adhesive layer26has a thickness of 300 μm to 500 μm. In some embodiments, the first adhesive layer26has a thickness of 300 μm to 450 μm. In some embodiments, the first adhesive layer26has a thickness of 300 μm to 400 μm. In some embodiments, the first adhesive layer26has a thickness of 300 μm to 350 μm.

In some embodiments, the first adhesive layer26has a thickness of 350 μm to 900 μm. In some embodiments, the first adhesive layer26has a thickness of 350 μm to 850 μm. In some embodiments, the first adhesive layer26has a thickness of 350 μm to 800 μm. In some embodiments, the first adhesive layer26has a thickness of 350 μm to 750 μm. In some embodiments, the first adhesive layer26has a thickness of 350 μm to 700 μm. In some embodiments, the first adhesive layer26has a thickness of 350 μm to 650 μm. In some embodiments, the first adhesive layer26has a thickness of 350 μm to 600 μm. In some embodiments, the first adhesive layer26has a thickness of 350 μm to 550 μm. In some embodiments, the first adhesive layer26has a thickness of 350 μm to 500 μm. In some embodiments, the first adhesive layer26has a thickness of 350 μm to 450 μm. In some embodiments, the first adhesive layer26has a thickness of 350 μm to 400 μm.

In some embodiments, the first adhesive layer26has a thickness of 400 μm to 900 μm. In some embodiments, the first adhesive layer26has a thickness of 400 μm to 850 μm. In some embodiments, the first adhesive layer26has a thickness of 400 μm to 800 μm. In some embodiments, the first adhesive layer26has a thickness of 400 μm to 750 μm. In some embodiments, the first adhesive layer26has a thickness of 400 μm to 700 μm. In some embodiments, the first adhesive layer26has a thickness of 400 μm to 650 μm. In some embodiments, the first adhesive layer26has a thickness of 400 μm to 600 μm. In some embodiments, the first adhesive layer26has a thickness of 400 μm to 550 μm. In some embodiments, the first adhesive layer26has a thickness of 400 μm to 500 μm. In some embodiments, the first adhesive layer26has a thickness of 400 μm to 450 μm.

In some embodiments, the first adhesive layer26has a thickness of 450 μm to 900 μm. In some embodiments, the first adhesive layer26has a thickness of 450 μm to 850 μm. In some embodiments, the first adhesive layer26has a thickness of 450 μm to 800 μm. In some embodiments, the first adhesive layer26has a thickness of 450 μm to 750 μm. In some embodiments, the first adhesive layer26has a thickness of 450 μm to 700 μm. In some embodiments, the first adhesive layer26has a thickness of 450 μm to 650 μm. In some embodiments, the first adhesive layer26has a thickness of 450 μm to 600 μm. In some embodiments, the first adhesive layer26has a thickness of 450 μm to 550 μm. In some embodiments, the first adhesive layer26has a thickness of 450 μm to 500 μm.

In some embodiments, the first adhesive layer26has a thickness of 500 μm to 900 μm. In some embodiments, the first adhesive layer26has a thickness of 500 μm to 850 μm. In some embodiments, the first adhesive layer26has a thickness of 500 μm to 800 μm. In some embodiments, the first adhesive layer26has a thickness of 500 μm to 750 μm. In some embodiments, the first adhesive layer26has a thickness of 500 μm to 700 μm. In some embodiments, the first adhesive layer26has a thickness of 500 μm to 650 μm. In some embodiments, the first adhesive layer26has a thickness of 500 μm to 600 μm. In some embodiments, the first adhesive layer26has a thickness of 500 μm to 550 μm.

In some embodiments, the first adhesive layer26has a thickness of 550 μm to 900 μm. In some embodiments, the first adhesive layer26has a thickness of 550 μm to 850 μm. In some embodiments, the first adhesive layer26has a thickness of 550 μm to 800 μm. In some embodiments, the first adhesive layer26has a thickness of 550 μm to 750 μm. In some embodiments, the first adhesive layer26has a thickness of 550 μm to 700 μm. In some embodiments, the first adhesive layer26has a thickness of 550 μm to 650 μm. In some embodiments, the first adhesive layer26has a thickness of 550 μm to 600 μm.

In some embodiments, the first adhesive layer26has a thickness of 600 μm to 900 μm. In some embodiments, the first adhesive layer26has a thickness of 600 μm to 850 μm. In some embodiments, the first adhesive layer26has a thickness of 600 μm to 800 μm. In some embodiments, the first adhesive layer26has a thickness of 600 μm to 750 μm. In some embodiments, the first adhesive layer26has a thickness of 600 μm to 700 μm. In some embodiments, the first adhesive layer26has a thickness of 600 μm to 650 μm.

In some embodiments, the first adhesive layer26has a thickness of 650 μm to 900 μm. In some embodiments, the first adhesive layer26has a thickness of 650 μm to 850 μm. In some embodiments, the first adhesive layer26has a thickness of 650 μm to 800 μm. In some embodiments, the first adhesive layer26has a thickness of 650 μm to 750 μm. In some embodiments, the first adhesive layer26has a thickness of 650 μm to 700 μm. In some embodiments, the first adhesive layer26has a thickness of 700 μm to 900 μm. In some embodiments, the first adhesive layer26has a thickness of 700 μm to 850 μm. In some embodiments, the first adhesive layer26has a thickness of 700 μm to 800 μm. In some embodiments, the first adhesive layer26has a thickness of 700 μm to 750 μm. In some embodiments, the first adhesive layer26has a thickness of 750 μm to 900 μm. In some embodiments, the first adhesive layer26has a thickness of 750 μm to 850 μm. In some embodiments, the first adhesive layer26has a thickness of 750 μm to 800 μm. In some embodiments, the first adhesive layer26has a thickness of 800 μm to 900 μm. In some embodiments, the first adhesive layer26has a thickness of 800 μm to 850 μm. In some embodiments, the first adhesive layer26has a thickness of 850 μm to 900 μm.

In some embodiments, the polymer layer24is composed of a fluoropolymer. In certain embodiments, the fluoropolymer may be ethylene tetrafluoroethylene (ETFE), fluoropolymer is polyvinylidene fluoride (PVDF), tetrafluoroethylene-hexafluoropropylene copolymers (FEP), and tetrafluoroethylene-hexafluoropropylene-vinylidene fluoride copolymers (THV), polyvinyl fluoride (PVF), or blends thereof. In some embodiments, the frontsheet is composed of fluoropolymers, acrylics, polyesters, silicones, polycarbonates, or combinations thereof. In other embodiments, the polymer layer24is composed of polyethylene terephthalate (PET), polyethylene naphthalate (PEN), polyetheretherketone (PEEK), polyaryletherketone (PAEK), polyarylate (PAR), polyetherimide (PEI), polyarylsulfone (PAS), polyethersulfone (PES), polyamideimide (PAI), polyphenylsulfone (PPSU), polyolefin, cyclic olefin copolymers (CPCs), or polyimide. In some embodiments, the polymer layer24is composed of a crosslinked polymeric material. In some embodiments, 50% to 99% of the polymer chains of the polymeric material are crosslinked.

In some embodiments, the polymer layer24has a thickness of 0.01 mm to 0.5 mm. In some embodiments, the polymer layer24has a thickness of 0.01 mm to 0.45 mm. In some embodiments, the polymer layer24has a thickness of 0.01 mm to 0.4 mm. In some embodiments, the polymer layer24has a thickness of 0.01 mm to 0.35 mm. In some embodiments, the polymer layer24has a thickness of 0.01 mm to 0.3 mm. In some embodiments, the polymer layer24has a thickness of 0.01 mm to 0.25 mm. In some embodiments, the polymer layer24has a thickness of 0.01 mm to 0.2 mm. In some embodiments, the polymer layer24has a thickness of 0.01 mm to 0.15 mm. In some embodiments, the polymer layer24has a thickness of 0.01 mm to 0.1 mm. In some embodiments, the polymer layer24has a thickness of 0.01 mm to 0.05 mm.

In some embodiments, the polymer layer24has a thickness of 0.05 mm to 0.5 mm. In some embodiments, the polymer layer24has a thickness of 0.05 mm to 0.45 mm. In some embodiments, the polymer layer24has a thickness of 0.05 mm to 0.4 mm. In some embodiments, the polymer layer24has a thickness of 0.05 mm to 0.35 mm. In some embodiments, the polymer layer24has a thickness of 0.05 mm to 0.3 mm. In some embodiments, the polymer layer24has a thickness of 0.05 mm to 0.25 mm. In some embodiments, the polymer layer24has a thickness of 0.05 mm to 0.2 mm. In some embodiments, the polymer layer24has a thickness of 0.05 mm to 0.15 mm. In some embodiments, the polymer layer24has a thickness of 0.05 mm to 0.1 mm.

In some embodiments, the polymer layer24has a thickness of 0.1 mm to 0.5 mm. In some embodiments, the polymer layer24has a thickness of 0.1 mm to 0.45 mm. In some embodiments, the polymer layer24has a thickness of 0.1 mm to 0.4 mm. In some embodiments, the polymer layer24has a thickness of 0.1 mm to 0.35 mm. In some embodiments, the polymer layer24has a thickness of 0.1 mm to 0.3 mm. In some embodiments, the polymer layer24has a thickness of 0.1 mm to 0.25 mm. In some embodiments, the polymer layer24has a thickness of 0.1 mm to 0.2 mm. In some embodiments, the polymer layer24has a thickness of 0.1 mm to 0.15 mm. In some embodiments, the polymer layer24has a thickness of 0.15 mm to 0.5 mm. In some embodiments, the polymer layer24has a thickness of 0.15 mm to 0.45 mm. In some embodiments, the polymer layer24has a thickness of 0.15 mm to 0.4 mm. In some embodiments, the polymer layer24has a thickness of 0.15 mm to 0.35 mm. In some embodiments, the polymer layer24has a thickness of 0.15 mm to 0.3 mm. In some embodiments, the polymer layer24has a thickness of 0.15 mm to 0.25 mm. In some embodiments, the polymer layer24has a thickness of 0.15 mm to 0.2 mm.

In some embodiments, the polymer layer24has a thickness of 0.2 mm to 0.5 mm. In some embodiments, the polymer layer24has a thickness of 0.2 mm to 0.45 mm. In some embodiments, the polymer layer24has a thickness of 0.2 mm to 0.4 mm. In some embodiments, the polymer layer24has a thickness of 0.2 mm to 0.35 mm. In some embodiments, the polymer layer24has a thickness of 0.2 mm to 0.3 mm. In some embodiments, the polymer layer24has a thickness of 0.2 mm to 0.25 mm. In some embodiments, the polymer layer24has a thickness of 0.25 mm to 0.5 mm. In some embodiments, the polymer layer24has a thickness of 0.25 mm to 0.45 mm. In some embodiments, the polymer layer24has a thickness of 0.25 mm to 0.4 mm. In some embodiments, the polymer layer24has a thickness of 0.25 mm to 0.35 mm. In some embodiments, the polymer layer24has a thickness of 0.25 mm to 0.3 mm.

In some embodiments, the polymer layer24has a thickness of 0.3 mm to 0.5 mm. In some embodiments, the polymer layer24has a thickness of 0.3 mm to 0.45 mm. In some embodiments, the polymer layer24has a thickness of 0.3 mm to 0.4 mm. In some embodiments, the polymer layer24has a thickness of 0.3 mm to 0.35 mm. In some embodiments, the polymer layer24has a thickness of 0.35 mm to 0.5 mm. In some embodiments, the polymer layer24has a thickness of 0.35 mm to 0.45 mm. In some embodiments, the polymer layer24has a thickness of 0.35 mm to 0.4 mm. In some embodiments, the polymer layer24has a thickness of 0.4 mm to 0.5 mm. In some embodiments, the polymer layer24has a thickness of 0.4 mm to 0.45 mm. In some embodiments, the polymer layer24has a thickness of 0.45 mm to 0.5 mm.

In some embodiments, the polymer layer24has a thickness of 0.01 mm. In some embodiments, the polymer layer24has a thickness of 0.05 mm. In some embodiments, the polymer layer24has a thickness of 0.1 mm. In some embodiments, the polymer layer24has a thickness of 0.15 mm. In some embodiments, the polymer layer24has a thickness of 0.2 mm. In some embodiments, the polymer layer24has a thickness of 0.25 mm. In some embodiments, the polymer layer24has a thickness of 0.3 mm. In some embodiments, the polymer layer24has a thickness of 0.35 mm. In some embodiments, the polymer layer24has a thickness of 0.4 mm. In some embodiments, the polymer layer24has a thickness of 0.45 mm. In some embodiments, the polymer layer24has a thickness of 0.5 mm.

In some embodiments, a backsheet28is juxtaposed with a second layer14bof the encapsulant14. In some embodiments, the backsheet28includes a first layer30. In some embodiments, the backsheet28includes a second layer32. In some embodiments, the first layer30is juxtaposed with the second layer14bof the encapsulant14. In some embodiments, the second layer32is juxtaposed with the first layer30. In some embodiments, the backsheet28only includes the first layer30(seeFIG.1B). In some embodiments, the photovoltaic module10does not include the backsheet28.

In some embodiments, the first layer30of the backsheet28is composed of a polymeric material. In some embodiments, the first layer30of the backsheet28is composed of polyethylene terephthalate (“PET”). In some embodiments, the first layer30of the backsheet28is composed of an acrylic such as polymethyl methacrylate (“PMMA”). In some embodiments, the first layer30of the backsheet28is composed of thermoplastic polyolefin (TPO). In some embodiments, the first layer30of the backsheet28includes of a single ply TPO roofing membrane. In other embodiments, non-limiting examples of TPO membranes are disclosed in U.S. Pat. No. 9,359,014 to Yang et al., which is incorporated by reference herein in its entirety. In another embodiment, the first layer30of the backsheet28is composed of polyvinyl chloride. In some embodiments, the first layer30of the backsheet28is composed of ethylene propylene diene monomer (EPDM) rubber. In some embodiments, the first layer30of the backsheet28is composed of polyvinyl chloride (PVC). In some embodiments, the first layer30of the backsheet28includes a flame retardant additive. In some embodiments, the flame retardant additive may be clays, nanoclays, silicas, carbon black, metal hydroxides such as aluminum hydroxide, metal foils, graphite, and combinations thereof. In some embodiments, the first layer30is white in color. In some embodiments, the first layer30is white TPO.

In some embodiments, the polymeric material may comprise, consist of, or consist essentially of at least one thermoplastic polymer, at least one recycled polymer, or any combination thereof. In some embodiments, the at least one thermoplastic polymer may comprise, consist of, or consist essentially of a polyolefin, a vinyl polymer, or any combination thereof. In some embodiments, the polyolefin may comprise, consist of, or consist essentially of polyethylene, polypropylene, or any combination thereof, such as, for example and without limitation, a copolymer of ethylene and propylene. In some embodiments, the polyolefin may comprise, consist of, or consist essentially of a copolymer of ethylene and an alpha-olefin, such as, for example and without limitation, ethylene and 1-octene, ethylene and 1-hexene, and ethylene and 1-butene. In some embodiments, the vinyl polymer may comprise, consist of, or consist essentially of a polyvinyl ester. In some embodiments, the vinyl polymer may comprise, consist of, or consist essentially of polyvinyl butyral (PVB). In some embodiments, the thermoplastic polymer may comprise, consist of, or consist essentially of a thermoplastic elastomer.

Some non-limiting examples of the polymeric materials (e.g., such as, one or more of thermoplastic polymers, polyolefins, vinyl polymers, polyvinyl esters, thermoplastic elastomers, recycled polymers, etc.) may include, without limitation, one or more of the following: polyethylenes (PE) (e.g., including, without limitation, one or more of raw low density polyethylene, recycled low density polyethylene (LDPE), linear low density polyethylene (LLDPE), and high density polyethylene (HDPE)), polypropylene (PP) (e.g., including, without limitation, one or more of isotactic polypropylene (IPP), atactic polypropylene/isotactic propylene (APP/IPP)), polystyrene, polyurethane (PU/TPU), polyurea, terpolymers (e.g., including, without limitation, a functionalized polymer with a reactive oxygen group), amorphous polyalpha olefins (APAO), amorphous polyolefins (APO), (e.g., including, without limitation, one or more of propylene homopolymers, copolymers of propylene and ethylene, copolymers of ethylene alpha-olefin, such as ethylene and 1-octene, ethylene and 1-hexene, and ethylene and 1-butene), polyolefin elastomers (POE), styrene/styrenic block copolymers (e.g., including, without limitation, one or more of styrenic block copolymers with a hydrogenated midblock of styrene-ethylene/butylene-styrene (SEBS), styrene-ethylene/propylene-styrene (SEPS), styrene-isoprene-styrene block copolymers (SIS), and styrene-butadiene-styrene block copolymers (SBS)), ethylene vinyl acetate (EVA), polyisobutylene, polybutadiene, oxidized polyethylene, epoxy thermoplastics, raw polyvinyl butyral (PVB), recycled polyvinyl butyral (rPVB), polyvinyl acetate (PVAC), poly(vinyl butyrate), poly(vinyl propionate), poly(vinyl formate), and copolymers of PVAC (e.g., including, without limitation, copolymers of PVAC and EVA). Some non-limiting examples of the at least one polymer (e.g., including, without limitation, thermoplastic polymers, polyolefins, vinyl polymers, polyvinyl esters, and thermoplastic elastomers) may include, without limitation, one or more of the following: Vistamaxx® 6102 and Vistamaxx® 8880, which are polypropylenes (e.g., isotactic polypropylene (IPP)) and which are available from ExxonMobil, Irving, Tex.; Elvaloy®, which is a terpolymer and which is available from Dow/DuPont, Wilmington, Del.; Fusabond®, which is a chemically modified ethylene acrylate copolymer, a modified polyethylene, or a combination thereof and which is available from Dow/DuPont, Wilmington, Del.; RT2304, which is an amorphous polyalpha olefin (APAO) and which is available from Rextac APAO Polymers LLC, Odessa, Tex.; Eastoflex® P1023, which is an amorphous polyolefin (APO) comprising a propylene homopolymer and which is available from Eastman Chemical Company, Kingsport, Tenn.; Eastoflex® E1060, which is an amorphous polyolefin (APO) comprising a copolymer of propylene and ethylene and which is available from Eastman Chemical Company, Kingsport, Tenn.; Eastoflex® M1025, which is an amorphous polyolefin (APO) that comprises a blend of propylene homopolymer and copolymers of propylene and ethylene and which is available from Eastman Chemical Company, Kingsport, Tenn.; Engage® 7487, which is a polyolefin elastomer (POE) and which is available from Dow Inc., Midland, Mich.; SEBS 1657, which is a linear triblock copolymer based on styrene and ethylene/butylene, namely, styrene-ethylene/butylene-styrene (SEBS) and which is available Kraton™ Corporation, Houston, Tex.; D0243, D0246, D1101, D1102, D1116, D1118, D1152, D1155, D1157, D1184, D1189, D1191, and D1194, which are styrene butadiene styrene block copolymers comprising blocks of styrene and butadiene and which is available Kraton™ Corporation, Houston, Tex.; PI131350, which is a polyisobutylene and which is available from TPC Group, Houston, Tex.; ethylene bis stearamide (EBS), which is available from ACME-Hardesty Company, Blue Bell, Pa.; IPP, which is available from Bay Polymer Corp., Fremont, Calif.; and recycled low density polyethylene, which is available from Avangard Innovative, Houston, Tex.

In some embodiments, the first layer30includes a non-asphalt (NAS) roofing material. In an embodiment, the NAS material includes a thermoplastic polymer. In some embodiments, the thermoplastic polymer includes at least one of a polyolefin, a vinyl polymer, and combinations thereof. In some embodiments, the polyolefin comprises one of (i) a polypropylene, (ii) a polyethylene, or (iii) a copolymer of propylene and ethylene. In an embodiment, the vinyl polymer is polyvinyl butyral (PVB). In some embodiments, the NAS material includes a filler. In an embodiment, the filler includes at least one of an organic filler, an inorganic mineral filler, or combinations thereof. In an embodiment, the filler is at least one of calcium carbonate, barium sulfate, calcium sulfate, talc, limestone, perlite, silica, fumed silica, precipitated silica, quartz, aluminum trihydrate, magnesium hydroxide, colemanite, titanium dioxide, snow white, fly ash, graphene nanoparticles, carbon black, recycled rubber tires, recycled shingles, recycled thermoplastic resins, basalt, roofing granules, clay, and combinations thereof. In other embodiments, non-limiting examples of NAS materials are disclosed in U.S. Patent Application Publication No. 2020/0224419 to Boss et al., which is incorporated by reference herein in its entirety.

In some embodiments, the first layer30is composed of fiberglass. In some embodiments, the first layer30is composed of a polymer with fiberglass. In some embodiments, the first layer30is composed of a synthetic roofing material. In some embodiments, the synthetic roofing material is a polyolefin coated, woven product. In some embodiments, the polyolefin coated, woven product comprises polypropylene.

In some embodiments, the first layer30has a thickness of 0.2 mm to 0.5 mm. In another embodiment, the first layer30has a thickness of 0.2 mm to 0.4 mm. In another embodiment, the first layer30has a thickness of 0.2 mm to 0.3 mm. In some embodiments, the first layer30has a thickness of 0.3 mm to 0.5 mm. In another embodiment, the first layer30has a thickness of 0.3 mm to 0.4 mm. In some embodiments, the first layer30has a thickness of 0.4 mm to 0.5 mm. In some embodiments, the first layer30has a thickness of 0.2 mm. In some embodiments, the first layer30has a thickness of 0.3 mm. In some embodiments, the first layer30has a thickness of 0.4 mm. In some embodiments, the first layer30has a thickness of 0.5 mm.

In some embodiments, the second layer32of the backsheet28is composed of one or more of the materials described above with respect to the first layer30of the backsheet28. In some embodiments, the second layer32is composed of the same material as the first layer30. In some embodiments, the second layer32is composed of substantially the same material as the first layer30. In some embodiments, the second layer32is composed of a different material than that of the first layer30.

In some embodiments, the second layer32has a thickness of 1 mm to 5 mm. In some embodiments, the second layer32has a thickness of 1 mm to 4 mm. In some embodiments, the second layer32has a thickness of 1 mm to 3 mm. In some embodiments, the second layer32has a thickness of 1 mm to 2 mm. In some embodiments, the second layer32has a thickness of 2 mm to 5 mm. In some embodiments, the second layer32has a thickness of 2 mm to 4 mm. In some embodiments, the second layer32has a thickness of 2 mm to 3 mm. In some embodiments, the second layer32has a thickness of 3 mm to 5 mm. In some embodiments, the second layer32has a thickness of 3 mm to 4 mm. In some embodiments, the second layer32has a thickness of 4 mm to 5 mm. In some embodiments, the second layer32has a thickness of 1 mm. In some embodiments, the second layer32has a thickness of 2 mm. In some embodiments, the second layer32has a thickness of 3 mm. In some embodiments, the second layer32has a thickness of 4 mm. In some embodiments, the second layer32has a thickness of 5 mm.

In some embodiments, the first layer30is attached to the second layer32by a second adhesive layer34. In some embodiments, the second adhesive layer34may include polyvinyl butyrate, acrylic, silicone, or polycarbonate. In another embodiment, the second adhesive layer34may include pressure sensitive adhesives.

In some embodiments, the second adhesive layer34has a thickness of 0.2 mm to 2 mm. In some embodiments, the second adhesive layer34has a thickness of 0.2 mm to 1.5 mm. In some embodiments, the second adhesive layer34has a thickness of 0.2 mm to 1 mm. In some embodiments, the second adhesive layer34has a thickness of 0.2 mm to 0.5 mm. In some embodiments, the second adhesive layer34has a thickness of 0.5 mm to 2 mm. In some embodiments, the second adhesive layer34has a thickness of 0.5 mm to 1.5 mm. In some embodiments, the second adhesive layer34has a thickness of 0.5 mm to 1 mm. In some embodiments, the second adhesive layer34has a thickness of 1 mm to 2 mm. In some embodiments, the second adhesive layer34has a thickness of 1 mm to 1.5 mm. In some embodiments, the second adhesive layer34has a thickness of 1.5 mm to 2 mm.

In some embodiments, the second adhesive layer34has a thickness of 0.2 mm. In some embodiments, the second adhesive layer34has a thickness of 0.3 mm. In some embodiments, the second adhesive layer34has a thickness of 0.4 mm. In some embodiments, the second adhesive layer34has a thickness of 0.45 mm. In some embodiments, the second adhesive layer34has a thickness of 0.5 mm. In some embodiments, the second adhesive layer34has a thickness of 1 mm. In some embodiments, the second adhesive layer34has a thickness of 1.5 mm. In some embodiments, the second adhesive layer34has a thickness of 2 mm. In some embodiments, the second adhesive layer34has a thickness of 2.5 mm. In some embodiments, the second adhesive layer34has a thickness of 3 mm. In some embodiments, the second adhesive layer34has a thickness of 3.5 mm. In some embodiments, the second adhesive layer34has a thickness of 4 mm.

In some embodiments, the second adhesive layer34has a thickness of 150 μm to 900 μm. In some embodiments, the second adhesive layer34has a thickness of 150 μm to 850 μm. In some embodiments, the second adhesive layer34has a thickness of 150 μm to 800 μm. In some embodiments, the second adhesive layer34has a thickness of 150 μm to 750 μm. In some embodiments, the second adhesive layer34has a thickness of 150 μm to 700 μm. In some embodiments, the second adhesive layer34has a thickness of 150 μm to 650 μm. In some embodiments, the second adhesive layer34has a thickness of 150 μm to 600 μm. In some embodiments, the second adhesive layer34has a thickness of 150 μm to 550 μm. In some embodiments, the second adhesive layer34has a thickness of 150 μm to 500 μm. In some embodiments, the second adhesive layer34has a thickness of 150 μm to 450 μm. In some embodiments, the second adhesive layer34has a thickness of 150 μm to 400 μm. In some embodiments, the second adhesive layer34has a thickness of 150 μm to 350 μm. In some embodiments, the second adhesive layer34has a thickness of 150 μm to 300 μm. In some embodiments, the second adhesive layer34has a thickness of 150 μm to 250 μm. In some embodiments, the second adhesive layer34has a thickness of 150 μm to 200 μm.

In some embodiments, the second adhesive layer34has a thickness of 200 μm to 900 μm. In some embodiments, the second adhesive layer34has a thickness of 200 μm to 850 μm. In some embodiments, the second adhesive layer34has a thickness of 200 μm to 800 μm. In some embodiments, the second adhesive layer34has a thickness of 200 μm to 750 μm. In some embodiments, the second adhesive layer34has a thickness of 200 μm to 700 μm. In some embodiments, the second adhesive layer34has a thickness of 200 μm to 650 μm. In some embodiments, the second adhesive layer34has a thickness of 200 μm to 600 μm. In some embodiments, the second adhesive layer34has a thickness of 200 μm to 550 μm. In some embodiments, the second adhesive layer34has a thickness of 200 μm to 500 μm. In some embodiments, the second adhesive layer34has a thickness of 200 μm to 450 μm. In some embodiments, the second adhesive layer34has a thickness of 200 μm to 400 μm. In some embodiments, the second adhesive layer34has a thickness of 200 μm to 350 μm. In some embodiments, the second adhesive layer34has a thickness of 200 μm to 300 μm. In some embodiments, the second adhesive layer34has a thickness of 200 μm to 250 μm.

In some embodiments, the second adhesive layer34has a thickness of 350 μm to 900 μm. In some embodiments, the second adhesive layer34has a thickness of 350 μm to 850 μm. In some embodiments, the second adhesive layer34has a thickness of 350 μm to 800 μm. In some embodiments, the second adhesive layer34has a thickness of 350 μm to 750 μm. In some embodiments, the second adhesive layer34has a thickness of 350 μm to 700 μm. In some embodiments, the second adhesive layer34has a thickness of 350 μm to 650 μm. In some embodiments, the second adhesive layer34has a thickness of 350 μm to 600 μm. In some embodiments, the second adhesive layer34has a thickness of 350 μm to 550 μm. In some embodiments, the second adhesive layer34has a thickness of 350 μm to 500 μm. In some embodiments, the second adhesive layer34has a thickness of 350 μm to 450 μm. In some embodiments, the second adhesive layer34has a thickness of 350 μm to 400 μm.

In some embodiments, the second adhesive layer34has a thickness of 400 μm to 900 μm. In some embodiments, the second adhesive layer34has a thickness of 400 μm to 850 μm. In some embodiments, the second adhesive layer34has a thickness of 400 μm to 800 μm. In some embodiments, the second adhesive layer34has a thickness of 400 μm to 750 μm. In some embodiments, the second adhesive layer34has a thickness of 400 μm to 700 μm. In some embodiments, the second adhesive layer34has a thickness of 400 μm to 650 μm. In some embodiments, the second adhesive layer34has a thickness of 400 μm to 600 μm. In some embodiments, the second adhesive layer34has a thickness of 400 μm to 550 μm. In some embodiments, the second adhesive layer34has a thickness of 400 μm to 500 μm. In some embodiments, the second adhesive layer34has a thickness of 400 μm to 450 μm.

In some embodiments, the second adhesive layer34has a thickness of 450 μm to 900 μm. In some embodiments, the second adhesive layer34has a thickness of 450 μm to 850 μm. In some embodiments, the second adhesive layer34has a thickness of 450 μm to 800 μm. In some embodiments, the second adhesive layer34has a thickness of 450 μm to 750 μm. In some embodiments, the second adhesive layer34has a thickness of 450 μm to 700 μm. In some embodiments, the second adhesive layer34has a thickness of 450 μm to 650 μm. In some embodiments, the second adhesive layer34has a thickness of 450 μm to 600 μm. In some embodiments, the second adhesive layer34has a thickness of 450 μm to 550 μm. In some embodiments, the second adhesive layer34has a thickness of 450 μm to 500 μm.

In some embodiments, the second adhesive layer34has a thickness of 500 μm to 900 μm. In some embodiments, the second adhesive layer34has a thickness of 500 μm to 850 μm. In some embodiments, the second adhesive layer34has a thickness of 500 μm to 800 μm. In some embodiments, the second adhesive layer34has a thickness of 500 μm to 750 μm. In some embodiments, the second adhesive layer34has a thickness of 500 μm to 700 μm. In some embodiments, the second adhesive layer34has a thickness of 500 μm to 650 μm. In some embodiments, the second adhesive layer34has a thickness of 500 μm to 600 μm. In some embodiments, the second adhesive layer34has a thickness of 500 μm to 550 μm.

In some embodiments, the second adhesive layer34has a thickness of 550 μm to 900 μm. In some embodiments, the second adhesive layer34has a thickness of 550 μm to 850 μm. In some embodiments, the second adhesive layer34has a thickness of 550 μm to 800 μm. In some embodiments, the second adhesive layer34has a thickness of 550 μm to 750 μm. In some embodiments, the second adhesive layer34has a thickness of 550 μm to 700 μm. In some embodiments, the second adhesive layer34has a thickness of 550 μm to 650 μm. In some embodiments, the second adhesive layer34has a thickness of 550 μm to 600 μm.

In some embodiments, the second adhesive layer34has a thickness of 600 μm to 900 μm. In some embodiments, the second adhesive layer34has a thickness of 600 μm to 850 μm. In some embodiments, the second adhesive layer34has a thickness of 600 μm to 800 μm. In some embodiments, the second adhesive layer34has a thickness of 600 μm to 750 μm. In some embodiments, the second adhesive layer34has a thickness of 600 μm to 700 μm. In some embodiments, the second adhesive layer34has a thickness of 600 μm to 650 μm.

In some embodiments, the second adhesive layer34has a thickness of 650 μm to 900 μm. In some embodiments, the second adhesive layer34has a thickness of 650 μm to 850 μm. In some embodiments, the second adhesive layer34has a thickness of 650 μm to 800 μm. In some embodiments, the second adhesive layer34has a thickness of 650 μm to 750 μm. In some embodiments, the second adhesive layer34has a thickness of 650 μm to 700 μm. In some embodiments, the second adhesive layer34has a thickness of 700 μm to 900 μm. In some embodiments, the second adhesive layer34has a thickness of 700 μm to 850 μm. In some embodiments, the second adhesive layer34has a thickness of 700 μm to 800 μm. In some embodiments, the second adhesive layer34has a thickness of 700 μm to 750 μm. In some embodiments, the second adhesive layer34has a thickness of 750 μm to 900 μm. In some embodiments, the second adhesive layer34has a thickness of 750 μm to 850 μm. In some embodiments, the second adhesive layer34has a thickness of 750 μm to 800 μm. In some embodiments, the second adhesive layer34has a thickness of 800 μm to 900 μm. In some embodiments, the second adhesive layer34has a thickness of 800 μm to 850 μm. In some embodiments, the second adhesive layer34has a thickness of 850 μm to 900 μm.

In another embodiment, the first layer30is attached to the second layer32by thermal bonding.

Referring toFIGS.2A through4, in some embodiments, the backsheet28includes a head flap40. In some embodiments, the head flap40is located at a first end42of the photovoltaic module10. In some embodiments, the backsheet28includes a bottom flap44located at a second end46of the photovoltaic module10. In some embodiments, the bottom flap44is located opposite the head flap40. In some embodiments, the backsheet28includes a first side flap48. In some embodiments, the first side flap48is located at a first side50of the photovoltaic module10. In some embodiments, the first side flap48extends from the first end42to the second end46. In some embodiments, the first side flap48extends from the head flap40to the bottom flap44. In some embodiments, the backsheet28includes a second side flap52. In some embodiments, the second side flap52is located at a second side54of the photovoltaic module10. In some embodiments, the second side flap52extends from the first end42to the second end46. In some embodiments, the second side flap52extends from the head flap40to the bottom flap44. In some embodiments, the head flap40, the bottom flap44, the first side flap48and the second side flap52are unitary with the backsheet28.

Referring toFIG.2B, in some embodiments, the head flap40includes a polymer layer55. In some embodiments, the polymer layer55is juxtaposed with the second layer14bof the encapsulant14. In some embodiments, the bottom flap44includes a polymer layer57. In some embodiments, the polymer layer57is juxtaposed with the second layer14bof the encapsulant14. In some embodiments, each of the polymer layers55,57is composed of a polymeric material. In some embodiments, each of the polymer layers55,57is composed of polyethylene terephthalate (“PET”). In some embodiments, each of the polymer layers55,57is composed of ethylene tetrafluoroethylene (“ETFE”). In some embodiments, each of the polymer layers55,57is composed of an acrylic such as polymethyl methacrylate (“PMMA”). In some embodiments, each of the polymer layers55,57is composed of thermoplastic polyolefin (TPO). In some embodiments, each of the polymer layers55,57is composed of polyvinyl chloride. In some embodiments, each of the polymer layers55,57is composed of ethylene propylene diene monomer (EPDM) rubber. In some embodiments, each of the polymer layers55,57is composed of HZF aramid reinforced polyamide.

In some embodiments, the polymer layer55has a thickness of 0.2 mm to 0.5 mm. In another embodiment, the polymer layer55has a thickness of 0.2 mm to 0.4 mm. In another embodiment, the polymer layer55has a thickness of 0.2 mm to 0.3 mm. In some embodiments, the polymer layer55has a thickness of 0.3 mm to 0.5 mm. In another embodiment, the polymer layer55has a thickness of 0.3 mm to 0.4 mm. In some embodiments, the polymer layer55has a thickness of 0.4 mm to 0.5 mm. In some embodiments, the polymer layer55has a thickness of 0.2 mm. In some embodiments, the polymer layer55has a thickness of 0.3 mm. In some embodiments, the polymer layer55has a thickness of 0.4 mm. In some embodiments, the polymer layer55has a thickness of 0.5 mm.

In some embodiments, the polymer layer57has a thickness of 0.2 mm to 0.5 mm. In another embodiment, the polymer layer57has a thickness of 0.2 mm to 0.4 mm. In another embodiment, the polymer layer57has a thickness of 0.2 mm to 0.3 mm. In some embodiments, the polymer layer57has a thickness of 0.3 mm to 0.5 mm. In another embodiment, the polymer layer57has a thickness of 0.3 mm to 0.4 mm. In some embodiments, the polymer layer57has a thickness of 0.4 mm to 0.5 mm. In some embodiments, the polymer layer57has a thickness of 0.2 mm. In some embodiments, the polymer layer57has a thickness of 0.3 mm. In some embodiments, the polymer layer57has a thickness of 0.4 mm. In some embodiments, the polymer layer57has a thickness of 0.5 mm.

In some embodiments, the photovoltaic module10is configured to be attached to a roofing membrane70of a roof deck. In some embodiments, the roof deck is a component of a commercial roof. In some embodiments, the roof deck is a component of a residential roof.

In some embodiments, the roof deck is a flat roof deck—that is, the roof deck has zero slope. In some embodiments, the roof deck has a slope of 3 inches per foot or less. In some embodiments, the roof deck has a slope of 0.25 inch to 3 inches per foot. In some embodiments, the roof deck has a slope of 0.25 inch to 2 inches per foot. In some embodiments, the roof deck has a slope of 0.25 inch to 1 inch per foot. In some embodiments, the roof deck has a slope of 1 inch to 3 inches per foot. In some embodiments, the roof deck has a slope of 1 inch to 2 inches per foot. In some embodiments, the roof deck has a slope of 2 inches to 3 inches per foot.

In some embodiments, the roof deck is a steep slope roof deck. As defined herein, a “steep slope roof deck” is any roof deck that is disposed on a roof having a pitch of Y/X, where Y and X are in a ratio of 4:12 to 12:12, where Y corresponds to the “rise” of the roof, and where X corresponds to the “run” of the roof.

In some embodiments, the roof deck is sloped (that is, the roof deck is not flat), but the roof deck has a slope less than that of a steep slope roof deck.

In some embodiments, the roofing membrane70is a preexisting roofing membrane installed on the roof deck. In some embodiments, an upper, outermost surface of the roofing membrane70opposite the roof deck is cleaned by a cleaning process.

In some embodiments, the head flap40is attached to the roofing membrane70. In some embodiments, the bottom flap44is attached to the roofing membrane70. In some embodiments, the first side flap48is attached to the roofing membrane70. In some embodiments, the second side flap52is attached to the roofing membrane70. In some embodiments, each of the first side flap48and the second side flap52is configured to prevent wind uplift. In an embodiment, the roofing membrane70is made from a polymeric material. In some embodiments, the roofing membrane70is composed of polyethylene terephthalate (“PET”). In another embodiment, the roofing membrane70is composed of ethylene tetrafluoroethylene (“ETFE”). In some embodiments, the roofing membrane70is composed of an acrylic such as polymethyl methacrylate (“PMMA”). In some embodiments, the roofing membrane70is composed of thermoplastic polyolefin (TPO). In some embodiments, the roofing membrane70is composed of polyvinyl chloride. In some embodiments, the roofing membrane70is composed of ethylene propylene diene monomer (EPDM) rubber. In some embodiments, the photovoltaic module10is attached to the roofing membrane70by an adhesive. In some embodiments, the adhesive is a peel and stick film sheet. In some embodiments, the peel and stick film sheet includes at least one sheet of film removably attached to a rear, lower most surface of the photovoltaic module10. In some embodiments, the peel and stick film sheet is composed of EverGuard Freedom HW peel and stick membrane manufactured by GAF. In some embodiments, the adhesive includes polyvinyl butyrate, acrylic, silicone, or polycarbonate. In some embodiments, the adhesive includes pressure sensitive adhesives. In some embodiments, the photovoltaic module10is attached to the roofing membrane70by thermal bonding. In some embodiments, the photovoltaic module10is attached to the roofing membrane70by ultrasonic welding. In some embodiments, the photovoltaic module10is attached to the roofing membrane70by heat welding. In some embodiments, the photovoltaic module10is attached to the roofing membrane70by induction welding. In some embodiments, the photovoltaic module10is attached to the roofing membrane70by hot air welding. In some embodiments, the photovoltaic module10is attached to the roofing membrane70by a mechanical crimping. In some embodiments, the photovoltaic module10is attached to the roofing membrane70by at least one fastener. In some embodiments, the at least one fastener includes a plurality of the fasteners. In some embodiments, the at least one fastener includes a nail. In some embodiments, the at least one fastener includes a screw. In some embodiments, the at least one fastener includes a rivet. In some embodiments, the at least one fastener includes a staple.

In some embodiments, the photovoltaic module10may be installed directly on the roof deck—that is, with no intervening member, membrane, component, composition, or additional layer, such as the roofing membrane70, between the roof deck and the photovoltaic module10. In some embodiments, the photovoltaic module10may be installed on the roof deck by any of the described ways of attaching the photovoltaic module10to another component, including by an adhesive, thermal bonding, ultrasonic welding, induction welding, hot air welding, mechanical crimping, and/or fasteners. In some other embodiments, the photovoltaic module10may be installed indirectly on the roofing deck, such that there is one or more intervening layers between the roof deck and the photovoltaic module10.

In some embodiments, at least a portion of the head flap40is attached to the roofing membrane70. In some embodiments, a width of 1 inch to 2 inches of the head flap40is attached to the roofing membrane70. In some embodiments, at least a portion of the bottom flap44is attached to the roofing membrane70. In some embodiments, a width of 1 inch to 2 inches of the bottom flap44is attached to the roofing membrane70. In some embodiments, the first side flap48is attached to the roofing membrane70. In some embodiments, a width of 1 inch to 2 inches of the first side flap48is attached to the roofing membrane70. In some embodiments, the second side flap52is attached to the roofing membrane70. In some embodiments, a width of 1 inch to 2 inches of the second side flap52is attached to the roofing membrane70.

In some embodiments, the photovoltaic module10includes at least one junction box56. In some embodiments, the at least one junction box56is located on a first surface41of the head flap40. In some embodiments, the at least one junction box56is attached to the first surface41of the head flap40. In some embodiments, the polymer layer55includes the first surface41. In some embodiments, the at least one junction box56is laminated within the head flap40. In some embodiments, the at least one junction box56is encapsulated within the encapsulant14. In some embodiments, the photovoltaic module10includes at least one module level power electronic component58. In some embodiments, the at least one module level power electronic component58is located on the first surface41of the head flap40. In some embodiments, the at least one module level power electronic component58is attached to the first surface41of the head flap40. In some embodiments, the at least one module level power electronic component58is laminated within the head flap40. In some embodiments, the photovoltaic module10includes at least one electrical connector60. In some embodiments, the photovoltaic module10includes at least one electrical connector60. In some embodiments, the at least one electrical connector60is a low profile electrical connector. In some embodiments, the at least one electrical connector60has a thickness of 1 mm to 10 mm. In some embodiments, the at least one electrical connector60is a flat ribbon cable. In some embodiments, the at least one electrical connector60is attached to the first surface41of the head flap40. In some embodiments, the at least one electrical connector60is laminated within the head flap40. In some embodiments, the photovoltaic module10includes at least one diode62. In some embodiments, the at least one diode62is laminated within the encapsulant14.

In some embodiments, the photovoltaic module10is configured (e.g., sized, shaped, positioned, made using a suitable material, etc.) such that it passes the UL 7103 standard for walkability (e.g., a “200 pound roofer test”). This test involves attaching the photovoltaic module10to a representative model of a roof and setting a 200-pound weight on a 3-inch diameter puck on the photovoltaic module10for 30 minutes. A photovoltaic module is deemed to pass the UL 7103 standard if there are no penetrations at the end of the 30-minute time period.

FIGS.5A through7show an embodiment of a photovoltaic module110. In some embodiments, the photovoltaic module110includes a structure and function similar to those of the photovoltaic module10, except for certain differences provided herein. In some embodiments, the photovoltaic module110includes a head flap140located at a first end142of the photovoltaic module110and a bottom flap144located at a second end146of the photovoltaic module110. In some embodiments, the head flap140incudes a first surface141and a second surface143opposite the first surface141. In some embodiments, the bottom flap144includes a first surface145and a second surface147opposite the first surface145.

In some embodiments, a free end148of the head flap140is bent and folded relative to itself such that it forms a rounded end149. In some embodiments, the head flap140includes one fold. In some embodiments, the rounded end149includes a first portion151juxtaposed with the roofing membrane170and a second portion153that is distal from the roofing membrane170. In some embodiments, the second portion153is elevated relative to the roofing membrane170. In an embodiment, the first surface141of at least the first portion151is attached to the roofing membrane170. In some embodiments, a second portion153of the rounded end149is elevated relative to the roofing membrane170, such that the photovoltaic module110is sloped at an angle A relative to the roofing membrane170. In some embodiments, the angle A is 0.1 degrees to 15 degrees. In some embodiments, the angle A is 0.1 degrees to 10 degrees. In some embodiments, the angle A is 0.1 degrees to 5 degrees. In some embodiments, the angle A is 5 degrees to 15 degrees. In some embodiments, the angle A is 5 degrees to 10 degrees. In some embodiments, the angle A is 10 degrees to 15 degrees. In some embodiments, the angle A is 5 degrees. In some embodiments, the angle A is 10 degrees. In some embodiments, the angle A is 15 degrees. In some embodiments, the angle A is 0.1 degree. In some embodiments, the angle A is 0 degrees. In some embodiments, at least a portion of the second surface147of the bottom flap144is attached to the roofing membrane170. In some embodiments, the photovoltaic module110is configured to be a watershedding layer of the roofing system. In some embodiments, the slope of the photovoltaic module110prevents water pooling thereon. In some embodiments, the first surface141of the head flap140includes indicia representing markings of the locations to attach the head flap140to the roofing membrane170to obtain the corresponding angle A. In some embodiments, the rounded end149includes a radius of curvature R.

In some embodiments, a space155is formed between the first portion151of the rounded end149and the second portion153of the rounded end149. In some embodiments, a junction box156is attached to the second surface143of the head flap140. In some embodiments, the junction box156is attached to the first surface141of the head flap140. In some embodiments, the junction box156is located within the space155. In some embodiments, the second portion153is perforated. In some embodiments, the second portion153includes perforations that are configured to release air within the space155, due to wind or otherwise, and prevent the first portion151from being detached from the roofing membrane170. In some embodiments, the rounded end149is configured to be flexible and collapsible for walkability. In some embodiments, the space155is sized and shaped to enable the rounded end149to be collapsible.

FIGS.8A through9show an embodiment of a photovoltaic module210. In some embodiments, the photovoltaic module210includes a structure and function similar to those of the photovoltaic module10, except for certain differences provided herein. In some embodiments, the photovoltaic module210includes a first portion211, a second portion213, and a region215located intermediate the first portion211and the second portion213. In some embodiment, the first portion211includes a first array of a plurality of solar cells212and the second portion213includes a second array of the plurality of solar cells212. In some embodiments, the region215extends from a first side250of the photovoltaic module210to a second side254of the photovoltaic module210opposite the first side250. In some embodiments, the region215is centrally-located. In some embodiments, the region215does not include any of the plurality of solar cells212. In some embodiments, the region215includes a reinforcing layer. In some embodiments, at least one electrical component260is located on a first surface241of the photovoltaic module210and within the region215. In some embodiments, at least one electrical component260is laminated within the photovoltaic module210and in the region215. In some embodiments, the at least one electrical component260includes a junction box. In some embodiments, the at least one electrical component260includes a diode. In some embodiments, the at least one electrical component260includes a module level power electronic component. In some embodiments, the at least one electrical component260includes an optimizer. In some embodiments, the at least one electrical component260includes an electrical connector. In some embodiments, the photovoltaic module210includes a cover262that covers the at least one electrical component260. In some embodiments, the cover262covers the region215.

In some embodiments, the cover262is composed of polyvinyl chloride. In some embodiments, the cover262is flexible. In some embodiments, the cover262is elastic. In some embodiments, the cover262is rigid.

In some embodiments, the first portion211of the photovoltaic module210includes a head flap240. In some embodiments, the head flap240is located proximate to the first array of the plurality of solar cells212. In some embodiments, the second portion213of the photovoltaic module210includes a bottom flap244. In some embodiments, the bottom flap244is located proximate to the second array of the plurality of solar cells212.

In some embodiments, the photovoltaic module210is attached to a roofing membrane270of a roofing system. In some embodiments, at least a portion of the head flap240is attached to the roofing membrane270. In some embodiments, at least a portion of the bottom flap244is attached to the roofing membrane270. In some embodiments, a support member275is positioned intermediate the roofing membrane270and a second surface243of the photovoltaic module210. In some embodiments, the support member275is located beneath the region215. In some embodiments, the support member275includes a rod. In some embodiments, the support member275includes a tubular rod. In an embodiment, the tubular rod is configured to receive electrical wire. In some embodiments, the support member275includes a cylindrical-shaped cross-section. In some embodiments, the support member275is square-shaped cross-section. In some embodiments, the support member275is rectangular-shaped cross-section. In some embodiments, the support member275includes a triangular-shaped cross-section. In some embodiments, the support member275includes an elliptical-shaped cross-section. In some embodiments, the support member275includes a U-shaped cross-section. In some embodiments, the support member275includes a base277. In some embodiments, the base277is flat. In some embodiments, the base277is attached to the roofing membrane270.

In some embodiments, the support member275is composed of a polymeric material. In some embodiments, the support member275is composed of polyethylene terephthalate (“PET”). In some embodiments, the support member275is composed of ethylene tetrafluoroethylene (“ETFE”). In some embodiments, the support member275is composed of an acrylic such as polymethyl methacrylate (“PMMA”). In some embodiments, the support member275is composed of thermoplastic polyolefin (TPO). In some embodiments, the support member275is composed of polyvinyl chloride. In some embodiments, the support member275is composed of ethylene propylene diene monomer (EPDM) rubber. In some embodiments, the support member275is composed of metal. In some embodiments, the support member275is flexible. In some embodiments, the support member275is elastic. In some embodiments, the support member275is rigid.

In some embodiments, the support member275elevates at least a portion of the photovoltaic module210over the roofing membrane270. In some embodiments, the support member275elevates the region215over the roofing membrane270. In some embodiments, the support member275elevates at least a portion of the first portion211over the roofing membrane270. In some embodiments, the support member275elevates at least a portion of the second portion213over the roofing membrane270. In some embodiments, the first portion211is sloped at an angle A relative to the roofing membrane270. In some embodiments, the angle A is 0.1 degrees to 15 degrees. In some embodiments, the angle A is 0.1 degrees to 10 degrees. In some embodiments, the angle A is 0.1 degrees to 5 degrees. In some embodiments, the angle A is 5 degrees to 15 degrees. In some embodiments, the angle A is 5 degrees to 10 degrees. In some embodiments, the angle A is 10 degrees to 15 degrees. In some embodiments, the angle A is 5 degrees. In some embodiments, the angle A is 10 degrees. In some embodiments, the angle A is 15 degrees.

In some embodiments, the second portion213is sloped at an angle B relative to the roofing membrane270. In some embodiments, the angle B is 0.1 degrees to 15 degrees. In some embodiments, the angle B is 0.1 degrees to 10 degrees. In some embodiments, the angle B is 0.1 degrees to 5 degrees. In some embodiments, the angle B is 5 degrees to 15 degrees. In some embodiments, the angle B is 5 degrees to 10 degrees. In some embodiments, the angle B is 10 degrees to 15 degrees. In some embodiments, the angle B is 0.1 degree. In some embodiments, the angle B is 5 degrees. In some embodiments, the angle B is 10 degrees. In some embodiments, the angle B is 15 degrees. In some embodiments, the angle B is 0 degrees. In some embodiments, the angle A is equal to the angle B. In some embodiments, the angle A is substantially the same as the angle B. In some embodiments, the angle A is different from the angle B. In some embodiments, the slopes of the photovoltaic module210prevent water pooling thereon.

In some embodiments, the region215is configured to be flexible and stretchable. In some embodiments, the region215is configured to be flexed and stretched when the support member275is positioned intermediate the region215and the roofing membrane270. In some embodiments, each of the first portion211and the second portion213is configured to be flexible and collapsible for walkability. Referring toFIGS.8B through8E, in some embodiments, the support member275is sized and shaped to enable the first portion211and the second portion213to be collapsible.

In some embodiments, each of the head flap240and the bottom flap244is attached to the roofing membrane270by an adhesive. In some embodiments, each of the head flap240and the bottom flap244is attached to the roofing membrane270by thermal bonding. In some embodiments, each of the head flap240and the bottom flap244is attached to the roofing membrane270by ultrasonic welding. Referring toFIG.10, in some embodiments, each of the head flap240and the bottom flap244is attached to the roofing membrane270by at least one fastener280. In some embodiments, the at least one fastener280includes a plurality of the fasteners280. In some embodiments, the at least one fastener280includes a nail. In some embodiments, the at least one fastener280includes a screw. In some embodiments, the at least one fastener280includes a rivet. In some embodiments, lower flaps282a,282bare positioned intermediate the head flap240and the roofing membrane270and the bottom flap244and the roofing membrane270, respectively.

Referring toFIGS.11A and11B, in some embodiments, the photovoltaic module10includes a plurality of the solar cells12, the encapsulant14encapsulating the solar cells12, the frontsheet16juxtaposed with one surface of the encapsulant14, and the backsheet28juxtaposed with another surface of the encapsulant14. In some embodiments, the backsheet28includes a first layer30. Any or all of the photovoltaic module10, the solar cells12, the encapsulant14, the frontsheet16, and/or the backsheet28may be as further described herein. As discussed, in some embodiments, the elements of the photovoltaic module10may be laminated with each other, such that the photovoltaic module10is in the form of a laminate.

In some embodiments, as shown inFIGS.11A and11B, the frontsheet16may include one or more, or all of, the glass layer22juxtaposed with the polymer layer24, and the polymer layer24attached to the glass layer22by the first adhesive layer26. Any or all of the glass layer22, the polymer layer24, and/or the first adhesive layer26may be as further described herein. In some embodiments, the frontsheet16may include the polymer layer24, while omitting the glass layer22and the first adhesive layer26.

In some embodiments, as shown inFIG.11A, the photovoltaic module10may include the backsheet28having the first layer30, and omitting other layers of the backsheet28described herein. However, in some embodiments, as shown inFIG.11B, the backsheet28may include the first layer30, the second layer32, and the second adhesive layer34attaching the first layer30and the second layer32. Any or all of the first layer30, the second layer32, and/or the second adhesive layer34may be as described herein. For example, as discussed, in some embodiments, one or more, or all of, the first layer30, the second layer32, and/or the second adhesive layer34may be composed of thermoplastic polyolefin (TPO). In some embodiments, the backsheet28may include the first layer30, while omitting the second layer32and the second adhesive layer34.

In some embodiments, as shown inFIG.12, the photovoltaic module10may be in the form of a roll400. In some embodiments, the photovoltaic module10may be rolled such that at least a portion of a surface17of the frontsheet16may be juxtaposed circumferentially with at least a portion of a surface31of the backsheet28when the photovoltaic module10is rolled upon itself. In some embodiments, the photovoltaic module10may be rolled such that at least a portion of a surface17of the frontsheet16contacts at least a portion of a surface31of the backsheet28when the photovoltaic module10is rolled upon itself. In some embodiments, when the photovoltaic module10is in the form of the roll400, the photovoltaic module10may be rolled such that either the surface17of the frontsheet16faces outward, or the surface31of the backsheet28faces outward. In some embodiments, the surface17of the frontsheet16faces outward and is visible and accessible on the outside of the roll400. In some embodiments, the surface31of the backsheet28faces outward.

In some embodiments, when the photovoltaic module10is the form of the roll400, the roll400includes a separate core about which the photovoltaic module10is rolled. In some embodiments, when the photovoltaic module10is rolled around the core, the core may be of a material such as but not limited to paper, cardboard, wood, plastic, combinations of one or more of these materials, and/or another material. In some embodiments, the core is not included in the roll400.

In some embodiments, in order for the photovoltaic module10to be in the form of the roll400, a distance between adjacent solar cells12, and/or a width of the solar cells12, may be sized to permit at least a portion of the surface of the frontsheet16to be juxtaposed circumferentially with at least a portion of the surface of the backsheet28. In some embodiments, the distances between adjacent ones of the solar cells12, as well as the widths of the solar cells12may be measured in a same direction. For example, in some embodiments, as shown inFIGS.11A and11B, distances D may separate adjacent ones of the solar cells12from one another, where distances D are measured in a first direction A. In some embodiments, the solar cells12may have widths WS, where the widths WS are measured in the first direction A. In some embodiments, the distances D separating adjacent ones of the solar cells12may be the same as one another—that is, the solar cells12may be separated from one another by the same distance. In some embodiments, the distances D separating adjacent ones of the solar cells12may be different from one another—that is, two of the solar cells12may be separated from one another by a first distance, while two of the solar cells12may be separated from one another by a second, different distance, for example. In some embodiments, the widths WS of different ones of the solar cells12, or all of the solar cells12, may be the same as one another. In some embodiments, the widths of at least some of the solar cells12may be different from one another—that is, at least one solar cell12may have a first width, and at least one other solar cell12may have a second, different width. The width(s) WS may or may not be the same as the distance(s) D. Further, in some embodiments, although not illustrated in the drawings, when the photovoltaic module10is laminated, the encapsulant14may flow between the solar cells12, such that the encapsulant14fully encapsulates the solar cells12.

In some embodiments, one or more properties of one or more of the polymer layer24, the first adhesive layer26, the glass layer22, the encapsulant14, the first layer30, the second adhesive layer34, and/or the second layer32may be chosen so as to permit the photovoltaic module10to be in the form of the roll400. These properties may include, for example, one or more thickness(es), and/or material(s) of the layers and adhesives.

In some embodiments, the solar cells12may be disposed within the photovoltaic module10such that the solar cells12are in the neutral plane of the photovoltaic module10when the photovoltaic module10is in the form of the roll400. In some embodiments, when the photovoltaic module10is in the form of the roll400and the solar cells12are in the neutral plane, the solar cells12are under neither tension nor compression. In some embodiments, the solar cells12may be disposed within the photovoltaic module10such that the solar cells12are under either tension or under compression when the photovoltaic module10is in the form of the roll400.

In some embodiments, as shown inFIG.12, the roll400may define a longitudinal axis300. In some embodiments, the longitudinal axis300of the roll400may extend in a second direction B that is perpendicular or substantially perpendicular to the first direction A in which the distance(s) between adjacent solar cells12and/or the width(s) of the solar cells12may be measured. Restated, the longitudinal axis300of the roll400may be parallel to or substantially parallel to the first direction A The second direction B, although not shown inFIG.11A, for example, extends into and out the page. Length(s) of one or more of the solar cells12may be measured in the second direction B

As discussed, in some embodiments, the photovoltaic module10may be installed directly on the roof deck—that is, with no intervening membrane, member, component, structure, or other layer, such as the roofing membrane70, between the roof deck and the photovoltaic module10. In some embodiments, the photovoltaic module10may be installed on the roof deck by an adhesive, thermal bonding, ultrasonic welding, induction welding, hot air welding, mechanical crimping, and/or fasteners, as discussed. In some other embodiments, the photovoltaic module10may be installed indirectly on the roofing deck, such that there is one or more intervening layers, members, components, structures, layers, and/or membranes between the roof deck and the photovoltaic module10.

In some embodiments, when the photovoltaic module10is in the form of the roll400as shown inFIG.12, the method of installation may include obtaining the roll400of the photovoltaic module10, as described, and unrolling the roll400of the photovoltaic module10.

Referring toFIG.13, in some embodiments, the photovoltaic module10includes a plurality of the solar cells12, the encapsulant14encapsulating the solar cells12, the frontsheet16juxtaposed with one surface of the encapsulant14, and the backsheet28juxtaposed with another surface of the encapsulant14. Any or all of the photovoltaic module10, the solar cell12, the encapsulant14, the frontsheet16, and/or the backsheet28may be as further described herein.

Also as shown inFIG.13, in some embodiments, the photovoltaic module10may include a support layer80, and/or may include a second encapsulant85. In some embodiments, the support layer80may be juxtaposed with a surface of the encapsulant14, as well as with a surface of the second encapsulant85. In some embodiments, the other surface of the second encapsulant85may be juxtaposed with a surface of the backsheet28. Any or all of the photovoltaic module10, the solar cells12, the encapsulant14, the frontsheet16, and/or the backsheet28may be as further described herein. In some embodiments, one or more properties of the second encapsulant85may be the same as or different than properties of the encapsulant14, such as, for example, the described thickness(es), and the described material(s).

In some embodiments, one or more properties of the support layer80may be the same as or different than properties of any or all of the polymer layer24, the first adhesive layer26, the glass layer22, the encapsulant14, the first layer30, the second adhesive34, and/or the second layer32, and/or the support member275, such as, for example, the described thickness(es) and/or the described material(s). In some embodiments, the use of the second encapsulant85and/or the support layer80may increase a rigidity of the photovoltaic module10as compared to the photovoltaic module10where either or both of the support layer80and/or the second encapsulant85are omitted. In some embodiments, although the figure shows the photovoltaic module10with the support layer80and the second encapsulant85as including the backsheet28with the first layer30, the second layer32, and the second adhesive34attaching the first layer30and the second layer32, the backsheet28need not include any or all of these layers. Thus, in some embodiments, the photovoltaic module10with the support layer80and the second encapsulant85may include the backsheet28with the first layer30and which omits the second layer32and the second adhesive layer34(that is, the backsheet28as shown inFIG.11A, for example).

In some embodiments, any of the disclosed layers from any of the described embodiments may be combined with one or more layers from one or more of any of the other embodiments, for example, to provide the photovoltaic module10that includes or omits and of the disclosed layers. Further, any of the photovoltaic modules10may be in the form of a laminate.

Any feature or element that is positively identified in this description may also be specifically excluded as a feature or element of an embodiment of the present as defined in the claims.

The disclosure described herein may be practiced in the absence of any element or elements, limitation or limitations, which is not specifically disclosed herein. The terms and expressions which have been employed are used as terms of description and not of limitation, and there is no intention in the use of such terms and expressions of excluding any equivalents of the features shown and described or portions thereof, but it is recognized that various modifications are possible within the scope of the disclosure.