Patent Description:
The active photovoltaic areas of photovoltaic apparatuses are often surrounded by supporting frames that can be used to route electrical connections and seal the photovoltaic apparatuses from the environment. These supporting frames represent inactive areas of photovoltaic apparatuses that do not produce energy. When multiple photovoltaic modules are arranged across a supporting structure (e.g., a roof), the photovoltaic modules are often positioned so that there is only a small gap between the frames of adjacent photovoltaic modules or the frames can alternatively contact each other to minimize the inactive photovoltaic areas on the supporting structure. However, even when photovoltaic modules contact each other, there is still a significant amount of area of the supporting structure that is not used to produce energy due to the area covered by the frames, which are inactive photovoltaic areas. Another problem with many photovoltaic modules is that thermal cycling can cause the transparent front sheet and/or a busbar of the photovoltaic module to delaminate from the laminated structure of the photovoltaic module. Such delamination can reduce the efficiency of a photovoltaic module and in some cases the delamination can lead to device failure.

For all photovoltaic modules, installation costs of the photovoltaic modules can form a significant portion of the overall costs of a photovoltaic system. Therefore, improvements that can reduce the amount of time required to install photovoltaic modules can reduce the overall cost of a photovoltaic system and make such photovoltaic systems more cost-competitive with traditional energy sources, such as fossil fuels.

<CIT> discloses a photovoltaic apparatus comprising an encapsulating front sheet comprising bends and wherein the back sheet comprises folds. <CIT> discloses a photovoltaic apparatus comprising a back sheet comprising legs and folds for anchoring to a rail. <CIT> discloses a photovoltaic apparatus comprising an encapsulating front sheet comprising bends, electrical output terminals, and wherein the back sheet comprises folds in a staircase-like geometry.

Therefore, there is a need for a photovoltaic apparatus that solves one or more of the problems described above.

It is to be noted, however, that the appended drawings illustrate only exemplary embodiments and are therefore not to be considered limiting of its scope, and may admit to other equally effective embodiments.

Embodiments of the present disclosure generally relate to photovoltaic apparatuses and assemblies of photovoltaic apparatuses. Embodiments of the present disclosure generally further relate to an arrangement of photovoltaic apparatuses that can be mounted on or connected to a supporting surface, such as a roof, building facade, wall or shading structure of a photovoltaic installation. Embodiments of the present disclosure generally further include the structure of a photovoltaic apparatus and a method of forming the same.

<FIG> is a top perspective view of a folded photovoltaic apparatus <NUM>, according to one embodiment. The photovoltaic apparatus <NUM> may include multiple optoelectronic devices, such as photovoltaic devices, diodes, and LEDs. The photovoltaic apparatus <NUM> is shown including three photovoltaic submodules <NUM>, <NUM>, <NUM> that each include one photovoltaic device <NUM> (<FIG>). Each photovoltaic device <NUM> can include multiple photovoltaic cells <NUM> (<FIG>). Each photovoltaic submodule <NUM>, <NUM>, <NUM> has a respective light-exposed surface <NUM>-F, <NUM>-F, <NUM>-F.

The photovoltaic apparatus <NUM> includes a first side <NUM> and a second side <NUM>. The first side <NUM> is spaced apart from the second side <NUM> in the X-direction. The photovoltaic apparatus <NUM> further includes a first end <NUM> and a second end <NUM>. The first end <NUM> is spaced apart from the second end <NUM> in the Y-direction. The photovoltaic apparatus <NUM> includes a first rigid folded portion <NUM> folded about a first bend-axis that is parallel to the X-axis at the first end <NUM> of the photovoltaic apparatus <NUM>. The photovoltaic apparatus <NUM> further includes a second rigid folded portion <NUM> folded about a second bend-axis that is parallel to the X-axis at the second end <NUM> of the photovoltaic apparatus <NUM>. As will be described in further detail below, the folded portions <NUM>, <NUM> may be rigid, which enables the photovoltaic apparatus <NUM> to be quickly installed in orientations that place less active areas of the photovoltaic apparatus <NUM>, such as areas covered by the busbars, at locations that receive less light than the more active areas of the photovoltaic apparatus <NUM>. Furthermore, the advantages offered by the rigid folded portions <NUM>, <NUM> enable multiple photovoltaic apparatuses <NUM> to be installed next to each other in such a way that the less active areas of the multiple photovoltaic apparatuses <NUM> are placed at locations that receive less light than the active areas of the photovoltaic apparatuses <NUM> while the less active areas of the photovoltaic apparatuses <NUM> only cover a very small percentage of a surface supporting the photovoltaic apparatuses, such as a roof.

Cutaway 1000A in the lower right-hand corner of <FIG> illustrates how the rigid folded portions <NUM>, <NUM> divide the photovoltaic apparatus into separate portions. For example, the first rigid folded portion <NUM> connects an intermediate first portion <NUM> to a second portion <NUM>. The second rigid folded portion <NUM> connects the intermediate first portion <NUM> to a third portion <NUM>. The intermediate first portion <NUM> has a first surface <NUM> facing the Z-direction. The photovoltaic apparatus <NUM> can be positioned on a supporting surface (e.g., a roof), so that the intermediate first portion <NUM> can face a direction with the most light exposure. Although the intermediate first portion <NUM> is largely shown as being substantially horizontal having a flat, light-exposed surface, in some embodiments the light-exposed surface of the intermediate first portion <NUM> can be a curved surface, a convex surface, a concave surface, or a wavy surface.

The second portion <NUM> can be located in a different position in the Z-direction from the intermediate first portion <NUM>. The third portion <NUM> can also be located in a different position in the Z-direction from the intermediate first portion <NUM>. The second portion <NUM> and the third portion <NUM> can represent portions of the photovoltaic apparatus <NUM> that are less active (i.e., portions that generate less photovoltaic energy per unit area) than the intermediate first portion <NUM>. As will be described below, the second portion <NUM> and the third portion <NUM> each include a busbar for making electrical connections to one or more of the photovoltaic devices, and these busbars can block light which reduces the amount of photovoltaic energy that can be produced in the second portion <NUM> and the third portion <NUM>. In some embodiments, the first surface <NUM> can be substantially flat and the second portion <NUM> and the third portion <NUM> can each be substantially perpendicular to the first surface <NUM>. In some embodiments, the first surface <NUM> can be substantially flat and the second portion <NUM> and the third portion <NUM> can each be positioned at an angle to the first surface <NUM>, such as at an angle greater than <NUM>° to a plane that is parallel to the first surface, or an angle greater than or equal to <NUM>° to a plane that is parallel to the first surface. In other embodiments, the first surface <NUM> can be a curved, convex, concave or wavy surface.

In some embodiments, the rigid folded portions <NUM>, <NUM> can be replaced by a folded portion having a clearly defined corner, such that the intermediate first portion <NUM> can meet the first rigid folded portion <NUM> or second rigid folded portion <NUM> at a corner without any noticeable curve. The folded portions <NUM>, <NUM> can form a curve that extends in both the Y and Z-directions. In some embodiments, the second portion <NUM> and the third portion <NUM> can extend substantially in a vertical plane (e.g., a unitless slope > <NUM> while still possibly including one or more curves), such as the X-Z plane. Similarly, the intermediate first portion <NUM> can extend substantially in a horizontal plane (e.g., a unitless slope < <NUM> while still possibly including one or more curves), such as the X-Y plane. One will note that the use of the phrases vertical plane and horizontal plane herein is not intended to limit the scope of the disclosure provided herein in, and is only intended to describe the orientation of the planes relative to each other versus the orientation of the planes to the world since the photovoltaic apparatus <NUM> can be installed or positioned in any desired orientation when in use.

The photovoltaic apparatus <NUM> includes a first busbar <NUM> extending adjacent to the first end <NUM> of the photovoltaic apparatus <NUM> and a second busbar <NUM> extending adjacent to the second end <NUM> of the photovoltaic apparatus <NUM>. The busbars <NUM>, <NUM> can be used to make electrical connections, for example electrical connections of opposite polarity, to the photovoltaic devices <NUM> shown in <FIG>. The busbars <NUM>, <NUM> can be formed of a rigid or flexible material. The busbars <NUM>, <NUM> are generally formed of a non-transparent conductive material, such as a conductive metal (e.g. a copper busbar) that is disposed over a portion of the photovoltaic device (i.e., the light-exposed side). Thus, the areas where the non-transparent busbars of a photovoltaic apparatus are positioned generally include areas that do not generate energy.

In some embodiments, the first busbar <NUM> can be disposed partially or entirely in the second portion <NUM>. Similarly, the second busbar <NUM> can be disposed partially or entirely in the third portion <NUM>. By positioning the busbars <NUM>, <NUM> in the corresponding portions <NUM>, <NUM>, the busbars <NUM>, <NUM> are located on a portion of the photovoltaic apparatus <NUM> that receives, over the course of an average day, less light per unit area than portions oriented to generate energy. When two photovoltaic apparatuses <NUM> are placed closely next to each other, for example in an adjacent configuration, such that a busbar in one of the photovoltaic apparatuses <NUM> is facing a busbar in the other photovoltaic apparatus <NUM> (e.g., within less than <NUM> centimeters, such as less than <NUM>), these two busbars can be located on portions of the respective photovoltaic apparatuses that may receive even less light on average because of mutual shading of these portions by the adjacent photovoltaic apparatuses <NUM>. By positioning the busbars <NUM>, <NUM> in areas that receive less light on average, a larger proportion of a structure's supporting surface (e.g., exterior surface of a roof) can be covered by the active areas of the photovoltaic apparatuses <NUM> that generate energy. Furthermore, the portions <NUM>, <NUM> can be oriented substantially perpendicular to the intermediate first portion <NUM> as well as substantially perpendicular to the supporting structure (e.g., a roof), which substantially reduces the surface area of the supporting structure that the portions <NUM>, <NUM> cover. Therefore, more energy can be generated for a given large area of the surface of the supporting structure (i.e., an area large enough to support multiple photovoltaic apparatuses spaced apart from each other on the supporting structure) covered by the photovoltaic apparatuses <NUM> than by a similar photovoltaic apparatus that does not include the portions <NUM>, <NUM>.

The photovoltaic apparatus <NUM> can further include a first rail <NUM> and a second rail <NUM>. The rails <NUM>, <NUM> can be formed of folded portions of a back sheet <NUM> described in fuller detail below. The rails <NUM>, <NUM> can be used to reduce the amount of time to install the photovoltaic apparatus <NUM>. For example, in one embodiment the rails <NUM>, <NUM> can be snapped into respective channels, such as channels formed in respective I-beams that are mounted to a supporting surface, such as a roof. In some embodiments, the rails <NUM>, <NUM> can also apply a pressure to the first surface <NUM> or other exposed surfaces, which can help to prevent delamination of the front sheet <NUM> (described in fuller detail in reference to <FIG>) and the respective busbars <NUM>, <NUM>. The rail can extend for all or for portion of the length of the photovoltaic apparatus <NUM> in the X-direction. Furthermore, in some embodiments the rails <NUM>, <NUM> may include one or more orifices <NUM> to promote drainage of water that may accumulate inside the rails <NUM>, <NUM>.

The photovoltaic apparatus <NUM> can further include a junction box <NUM>. The junction box <NUM> includes a first cable <NUM> having a first connector <NUM>. Although not shown the first cable <NUM> can be electrically connected to the first busbar <NUM> by use of one or more junction busbars or other conductors. The junction box <NUM> further includes a second cable <NUM> having a second connector <NUM>. Although not shown the second cable <NUM> can be electrically connected to the second busbar <NUM> by use of one or more junction busbars or other conductors. The junction box <NUM> can be used to electrically connect the photovoltaic apparatus <NUM> to an external device, such as another photovoltaic apparatus <NUM>, a charge controller or other electronics for charging one or more power sources (e.g., a battery bank), or electrical systems that may be used to feed electrical power to an electrical grid.

<FIG> is a top schematic view of the photovoltaic apparatus <NUM> prior to bending the photovoltaic apparatus <NUM> to form the rigid folded portions <NUM>, <NUM> and the rails <NUM>, <NUM>, according to one embodiment. The top schematic view of <FIG> illustrates the layout of different components in the photovoltaic apparatus <NUM> although some of these components may not actually be visible in a top view. The photovoltaic apparatus <NUM> includes the three photovoltaic submodules <NUM>, <NUM>, <NUM>. Each photovoltaic submodule <NUM>, <NUM>, <NUM> includes a photovoltaic device <NUM>. Other embodiments of the photovoltaic apparatus <NUM> may include more than three photovoltaic devices <NUM> spaced apart from each other in the X-direction and/or the Y-direction. These other embodiments of the photovoltaic apparatus <NUM> can include, for example, photovoltaic devices <NUM> connected in series or in parallel as well as photovoltaic devices <NUM> that are not electrically connected to each other.

The photovoltaic device <NUM> includes an array of photovoltaic cells <NUM> extending from a first end <NUM> to a second end <NUM> in the Y-direction. Individual photovoltaic cells <NUM>, extend from a first side <NUM> to a second side <NUM> of the photovoltaic device <NUM> in the X-direction. Serial interconnects <NUM> (e.g., monolithic serial interconnects) electrically divide the photovoltaic cells <NUM>, so that consecutive photovoltaic cells <NUM> in the array are connected in series. In some embodiments, the serial interconnects <NUM> and the folding axis for one or more of the folded portions <NUM>, <NUM> can extend in the same direction (e.g., the X-direction).

Furthermore, in some embodiments, the serial interconnect <NUM> between one or more pairs of photovoltaic cells <NUM> in the array can be located in one of the rigid folded portions <NUM>, <NUM>. The serial interconnects <NUM> of the photovoltaic device <NUM> can be areas with greater flexibility than other areas of the photovoltaic device <NUM>, so forming the folded portions <NUM>, <NUM> about a folding axis that extends in the same direction as the serial interconnects <NUM> or that coincide with the serial interconnects <NUM> can place less stress on the photovoltaic apparatus <NUM> during folding. Furthermore, in some embodiments the serial interconnects <NUM> can be thicker in the Y-direction (i.e., the direction of the array) for serial interconnects located in the folded or curved portions <NUM>, <NUM>, to further enhance the flexibility of the photovoltaic apparatus <NUM> at the folded portions <NUM>, <NUM>.

In some embodiments, a bypass diode (not shown) may be electrically connected in parallel to locations of opposite polarity of individual photovoltaic cells <NUM> that are in the folded portions <NUM>, <NUM>. For example, in one embodiment a bypass diode may be connected in the reverse bias direction to the busbar <NUM> and the serial interconnect <NUM> between the first photovoltaic cell <NUM> and the second photovoltaic cell <NUM> in the array. Using bypass diodes in these locations can help prevent the effects of having portions of one or more of the photovoltaic cells <NUM> that are shaded from the sun (e.g., reverse bias effect) and/or hot-spot heating. Thus, in some embodiments, it is desirable to form the photovoltaic apparatus <NUM> such that none of the photovoltaic cells <NUM> are shaded, or even partially shaded, during normal use within an array of photovoltaic apparatuses. In other words, in some embodiments, all of the photovoltaic cells <NUM> (e.g., active portion of the photovoltaic device) are substantially disposed within the intermediate first portion <NUM>. In other embodiments, only a small portion of the last photovoltaic cells <NUM> disposed at either end of the photovoltaic apparatus <NUM> in the Y-direction is disposed in the rigid folded portions <NUM>, <NUM>. In other embodiments, only a small portion of the last photovoltaic cells <NUM> disposed at either end of the photovoltaic apparatus <NUM> in the Y-direction is disposed in the portions <NUM>, <NUM>.

After the photovoltaic apparatus <NUM> is folded (i.e., folds or curves <NUM>, <NUM> are formed), the first end <NUM> of each photovoltaic device <NUM> can be located in the second portion <NUM> (<FIG>) and the second end <NUM> can be located in the third portion <NUM> (<FIG>). Placing the ends <NUM>, <NUM> in the portions <NUM>, <NUM> allows the portions of the photovoltaic device <NUM> that are covered by the busbars <NUM>, <NUM> to be oriented substantially perpendicular to the supporting surface (e.g., a roof), so that these lower power-generating portions of the photovoltaic device <NUM> do not cover a significant proportion of the surface area exposed to the sun and the surface area of the supporting surface of the photovoltaic installation.

<FIG> is a side cross-sectional view of the photovoltaic submodule <NUM> of the photovoltaic apparatus <NUM> viewed along the section line 1C of <FIG>, according to one embodiment. The view in <FIG> shows the layers of the photovoltaic apparatus <NUM> in the intermediate first portion <NUM>, which is away from the rigid folded portions <NUM>, <NUM> of the photovoltaic apparatus <NUM>. The photovoltaic submodules <NUM> of the photovoltaic apparatus <NUM> includes the photovoltaic device <NUM> introduced above. The photovoltaic device <NUM> is formed on a substrate <NUM>. In some embodiments, the substrate <NUM> may be a rigid substrate. In other embodiments, the substrate <NUM> can be a flexible substrate. Other embodiments may include a plurality of substrates, for example stacked on top of one another, in which some of the substrates are rigid and some of the substrates are flexible. The substrate <NUM> may also be formed from an electrically insulating material. For example, in one embodiment a polyimide substrate may be used, such as a polyimide substrate having a thickness in the Z-direction from about <NUM> to about <NUM>, such as from about <NUM> to about <NUM>.

In some embodiments, the photovoltaic device <NUM> can be thin-film layers deposited on the substrate <NUM>, such as scribed thin-film layers including a plurality of monolithically interconnected photovoltaic cells, such as the photovoltaic cells <NUM> described above. In other embodiments, the photovoltaic device <NUM> can include a photovoltaic device formed on another substrate that is then positioned on the substrate <NUM>.

The photovoltaic device <NUM> can be formed of, for example, a back-contact layer formed on the substrate <NUM>, an absorber layer formed over the back-contact layer, and a front-contact layer formed over the absorber layer. The back-contact layer can be fabricated from a material having a high optical reflectance and is commonly made of molybdenum (Mo) although several other thin-film materials, such as metal chalcogenides, molybdenum chalcogenides, molybdenum selenides (such as MoSe<NUM>), sodium (Na)-doped Mo, potassium (K)-doped Mo, Na- and K-doped Mo, transition metal chalcogenides, tin-doped indium oxide (ITO), doped or non-doped indium oxides, doped or non-doped zinc oxides, zirconium nitrides, tin oxides, titanium nitrides, titanium (Ti), tungsten (W), tantalum (Ta), gold (Au), silver (Ag), copper (Cu), and niobium (Nb) may also be used or included advantageously. In some embodiments, the back-contact layer is deposited onto the substrate <NUM> by use of sputtering process.

The absorber layer is typically made of an "ABC" material, wherein "A" represents elements in group <NUM> of the periodic table of chemical elements as defined by the International Union of Pure and Applied Chemistry including copper (Cu) or silver (Ag), "B" represents elements in group <NUM> of the periodic table including indium (In), gallium (Ga), or aluminum (Al), and "C" represents elements in group <NUM> of the periodic table including sulfur (S), selenium (Se) or tellurium (Te). An example of an ABC material is the Cu(In,Ga)Se2 semiconductor also known as CIGS. In some embodiments, the absorber layer may be a polycrystalline material. In other embodiments, the absorber layer may be a monocrystalline material. Another example of a material that may be used as the absorber layer is chalcopyrite.

The front-contact layer can be an electrically conductive and optically transparent material, such as a transparent conductive oxide (TCO) layer. For example, in some embodiments, the front-contact layer may be formed of doped or non-doped variations of materials, such as indium oxides, tin oxides, or zinc oxides.

In some embodiments, a semiconductive buffer layer can be disposed between the absorber layer and the front-contact layer. The semiconductive buffer layer ordinarily has an energy bandgap higher than <NUM> eV. The semiconductive buffer layer may be formed of materials, such as CdS, Cd(S,OH), CdZnS, indium sulfides, zinc sulfides, gallium selenides, indium selenides, compounds of (indium, gallium)-sulfur, compounds of (indium, gallium)-selenium, tin oxides, zinc oxides, Zn(Mg,O)S, Zn(O,S) material, or variations thereof.

The first busbar <NUM> (<FIG>) forms an electrical connection to the first end <NUM> of the photovoltaic device <NUM>, such as to the back-contact layer through a connection region of the front-contact layer of the photovoltaic device <NUM> that is coupled to the back-contact layer at the first end <NUM> of the photovoltaic device <NUM>. The first busbar <NUM> may be a conductive material that forms the cathode of the photovoltaic device <NUM>. In some embodiments, the first busbar <NUM> may be formed of a flexible material.

The second busbar <NUM> (<FIG>) forms an electrical connection to the second end <NUM> of the photovoltaic device <NUM>, such as to the front-contact layer of the photovoltaic device <NUM> at the second end <NUM> of the photovoltaic device <NUM>. The second busbar <NUM> may be a conductive material that forms the anode of the photovoltaic device <NUM>. In some embodiments, the second busbar <NUM> may be formed of a flexible material.

The photovoltaic device <NUM> may be encapsulated within the photovoltaic apparatus <NUM> by use of a front-side adhesive <NUM> and a back-side adhesive <NUM>. In some embodiments, the front-side adhesive <NUM> and the back-side adhesive <NUM> completely surround and encapsulate the photovoltaic device <NUM>. The front-side adhesive <NUM> is formed over the front-contact layer. of each of the photovoltaic device <NUM>, and also over the first and second busbars <NUM>, <NUM>. The front-side adhesive <NUM> may be formed of a flexible material, such as a flexible polymer. For example, in one embodiment the front-side adhesive <NUM> may be formed of a thermoplastic olefin (TPO) based polymer or a TPO blend.

The back-side adhesive <NUM> is disposed over the side of the substrate <NUM> that is opposite to the side that the photovoltaic device <NUM> is formed on. The back-side adhesive <NUM> may be formed of a flexible material, such as a flexible polymer. For example, in one embodiment the back-side adhesive <NUM> may be formed of a thermoplastic olefin-based polymer (TPO) or a TPO polymer blend. The back-side adhesive <NUM> may contact the front-side adhesive <NUM> at each side of the photovoltaic device <NUM> (i.e., along the sides <NUM>, <NUM> of the photovoltaic apparatus <NUM> in <FIG>) and also at either end of the photovoltaic device <NUM> (i.e., along the ends <NUM>, <NUM> of the photovoltaic apparatus <NUM> of <FIG>), so that the front-side adhesive <NUM> and the back-side adhesive <NUM> completely surround and encapsulate the photovoltaic device <NUM>.

Referring to <FIG> and <FIG>, a front sheet <NUM> can be disposed on an outer surface of the front-side adhesive <NUM>, such as a top surface of the front-side adhesive <NUM>. The front sheet <NUM> can be formed of a transparent material, such as glass or a transparent thermoplastic polymer. In some embodiments, the front sheet <NUM> may be formed of a rigid material or a material that is rigid at ambient temperature. In other embodiments, the front sheet <NUM> may be formed of a flexible material. In other embodiments, the front sheet <NUM> may be formed of an assembly of flexible and rigid materials. The front sheet <NUM> can extend at least partially through each of the second portion <NUM>, the first rigid folded portion <NUM>, the intermediate first portion <NUM>, the second rigid folded portion <NUM>, and the third portion <NUM>. In some embodiments, the front sheet <NUM> can extend in the Y-direction across the entire first rigid folded portion <NUM>, the entire intermediate first portion <NUM>, and the entire second rigid folded portion <NUM>.

The outer surface of the back-side adhesive <NUM>, such as a bottom surface of the back-side adhesive <NUM>, can be disposed on a back sheet <NUM>. The back sheet <NUM> may include a reflective material, such as a metallic layer, a reflective polymer or a polymer with a reflective layer (e.g., metal foil). In some embodiments, the back sheet <NUM> may be formed of a rigid material, such as a bendable rigid material. In other embodiments, the back sheet <NUM> may be formed of a flexible material, such as a bendable flexible material. In some embodiments, the back sheet <NUM> can be formed of a non-transparent material, such as a non-transparent metal. Other examples of materials that may be used to form the back sheet <NUM> include metal, stainless steel, aluminum, polymers, and fiber-reinforced polymers. Referring to <FIG>, the back sheet <NUM> can extend at least partially through each of the second portion <NUM>, the first rigid folded portion <NUM>, the intermediate first portion <NUM>, the second rigid folded portion <NUM>, and the third portion <NUM>. In some embodiments, the back sheet <NUM> can extend in the Y-direction across the entire second portion <NUM>, the entire first rigid folded portion <NUM>, the entire intermediate first portion <NUM>, the entire second rigid folded portion <NUM>, and the entire third portion <NUM>. The photovoltaic device <NUM> is disposed between the front sheet <NUM> and the back sheet <NUM>. In some embodiments, photovoltaic devices <NUM> are disposed between the front sheet <NUM> and the back sheet <NUM> in each of the intermediate first portion <NUM>, the second portion <NUM>, the third portion <NUM>, the first rigid folded portion <NUM>, and the second rigid folded portion <NUM>.

In some embodiments, the front sheet <NUM> can include an outer portion <NUM> that is bent towards the back sheet <NUM>. The bending of the outer portion <NUM> can be caused by pressure placed on the front sheet <NUM> during a lamination process used to adhere the different layers of the photovoltaic apparatus <NUM> to each other.

The photovoltaic apparatus <NUM> can further include an edge seal <NUM>. The presence of the edge seal <NUM> at the edge of the photovoltaic apparatus <NUM> can eliminate common photovoltaic apparatus manufacturing and photovoltaic device failure modes, such as ingress of moisture to the interior of the photovoltaic apparatus <NUM>. In general, the edge seal <NUM> comprises a polymeric material, such as an elastomer, for example a butyl rubber that can be formed by dispensing a liquid precursor material along the edge of the photovoltaic apparatus <NUM> and allowing it to cure. The edge seal <NUM> can be disposed between the back sheet <NUM> and the front sheet <NUM>.

In some embodiments, the photovoltaic apparatus <NUM> can further include a plurality of rovings <NUM> or other spacing material. The plurality of rovings <NUM> can be positioned on the back sheet <NUM> in some embodiments. Each roving <NUM> can be formed of a bundle of organic or inorganic fibers. The fibers in the rovings <NUM> may be formed of a fibrous material, such as fiberglass. In other embodiments, the rovings <NUM> may be formed of another fiber material, such as a carbon fiber material, or of a fabric. In other embodiments, the rovings <NUM> may be formed of a layer of a unidirectional glass fiber with a non-woven binder.

The rovings <NUM> can be embedded in the back-side adhesive <NUM> during a lamination process, which is used to form the photovoltaic apparatus <NUM>. Because the rovings <NUM> can be formed from a rigid material that can be arranged in a desirable structural pattern or orientation, such as fiberglass, the rovings <NUM> can be used to maintain a spacing between an electrically active component of the photovoltaic device <NUM>, such as the back-contact layer described above, and an external object. Furthermore, a material such as fiberglass generally does not substantially shrink or compress over time, which enables spacing between electrically active components and external objects to be maintained over time in the photovoltaic apparatus <NUM>. Maintaining adequate spacing between electrically active components of the photovoltaic device <NUM>, such as the back-contact layer described above, and an external object can help to prevent occurrences of arcing.

<FIG> is a side cross-sectional view of the photovoltaic apparatus <NUM> viewed along the section line 1D of <FIG>, according to one embodiment. The photovoltaic apparatus <NUM> is formed of a laminated structure including a first leg <NUM> having a base 407E, a second leg <NUM> having a base 408E, and an intermediate first portion <NUM> connecting the first leg <NUM> to the second leg <NUM>. Dividing line D-<NUM> illustrates the approximate position where the intermediate first portion <NUM> ends and the first leg <NUM> begins. Dividing line D-<NUM> illustrates the approximate position where the intermediate first portion <NUM> ends and the second leg <NUM> begins. Angle <NUM> shows that the straight portion of the legs <NUM>, <NUM> can be substantially at a right angle with respect to intermediate first portion <NUM>. In some embodiments, the legs <NUM>, <NUM> may be oriented at angles other than right angles with respect to the intermediate first portion <NUM>.

The first leg <NUM> can include the second portion <NUM> and the first rigid folded portion <NUM> shown in <FIG>. Similarly, the second leg <NUM> can include the third portion <NUM> and the second rigid folded portion <NUM> shown in <FIG>. The photovoltaic apparatus <NUM> further includes the rails <NUM>, <NUM>, which can be used to reduce the time required for installation of the photovoltaic apparatus <NUM> and to help prevent the busbars <NUM>, <NUM> and layers in the photovoltaic apparatus, such as the front sheet <NUM>, from delaminating from the laminated structure of the photovoltaic apparatus <NUM>. The first rail <NUM> extends from the base 407E of the first leg <NUM>. The second rail <NUM> extends from the base 408E of the second leg <NUM>.

For the photovoltaic apparatus <NUM>, the front sheet <NUM> extends through all of the intermediate first portion <NUM>, part of the first leg <NUM>, and part of the second leg <NUM>. However, in some embodiments, the front sheet <NUM> extends through at least part of each of the intermediate first portion <NUM>, the first leg <NUM>, and the second leg <NUM>. The front sheet <NUM> of the photovoltaic apparatus <NUM> includes a first portion <NUM> disposed in the intermediate first portion <NUM>, a second portion <NUM> disposed in the first leg <NUM>, and a third portion <NUM> disposed in the second leg <NUM>.

The back sheet <NUM> of the photovoltaic apparatus <NUM> can extend through all of the intermediate first portion <NUM>, all of the first leg <NUM>, and all of the second leg <NUM>. However, in some embodiments, the back sheet <NUM> extends through at least part of each of the intermediate first portion <NUM>, the first leg <NUM>, and the second leg <NUM>. The back sheet <NUM> of the photovoltaic apparatus <NUM> includes a first portion <NUM> in the intermediate first portion <NUM>, a second portion <NUM> in the first leg <NUM>, and a third portion <NUM> (first folded portion) extending from the base 407E of the first leg <NUM>.

An interior region <NUM> is formed between the first leg <NUM> and the second leg <NUM>. The third portion <NUM> of the back sheet <NUM> extends outward the interior region <NUM> from the base 407E. An interior angle between the first leg <NUM> and the third portion <NUM> of the back sheet <NUM> is less than <NUM> degrees. The back sheet <NUM> further includes a first curved portion <NUM> extending from the third portion <NUM> back towards the front sheet <NUM>. The curved portion <NUM> can be used to apply a pressure against the front sheet <NUM>, such as applying pressure against the second portion <NUM> of the front sheet <NUM>. In some embodiments, the first curved portion <NUM> can contact the front sheet <NUM>, such as contact the second portion <NUM> of the front sheet <NUM>. In some embodiments, the first curved portion <NUM> can have a rounded shape, such as a convex shape. Furthermore, in some embodiments, the first curved portion can have a cross-sectional thickness that allows it to deform elastically when pressure is applied to the first rail <NUM> towards the front sheet <NUM>. This elastic deformation can help to distribute the force applied by the curved portion <NUM> to the front sheet <NUM> over a larger area of the front sheet <NUM>, which can be beneficial for preventing the delamination of the front sheet <NUM> relative to applying all of the pressure on a smaller area of the front sheet <NUM>.

The second portion <NUM> of the front sheet <NUM> can be disposed in a space formed between the second portion <NUM> of the back sheet <NUM> and the third portion <NUM> of the back sheet <NUM> allowing the second portion <NUM> of the front sheet <NUM> to be compressed between the second portion <NUM> of the back sheet <NUM> and the third portion <NUM> of the back sheet <NUM>. In some embodiments, the pressure is applied by the curved portion <NUM> and indirectly by the third portion <NUM>. Furthermore, the busbar <NUM> is disposed between the third portion <NUM> of the back sheet <NUM> and the second portion <NUM> of the back sheet <NUM>. Placing the second portion <NUM> of the front sheet <NUM> and the busbar <NUM> between the second portion of the back sheet <NUM> and the third portion <NUM> of the back sheet <NUM> can help prevent the front sheet <NUM> and the busbar <NUM> from delaminating from the laminated structure of the photovoltaic apparatus <NUM> when the third portion <NUM> or the first curved portion <NUM> applies a pressure against the front sheet <NUM> after the rail <NUM> of the photovoltaic apparatus <NUM> is placed in a supporting channel as described below in reference to <FIG>.

The edge seal <NUM> can be placed in areas between the third portion <NUM> of the back sheet <NUM> and the second portion <NUM> of the back sheet <NUM>, between the third portion <NUM> of the back sheet <NUM> and the front sheet <NUM> as well as between the curved portion <NUM> and the front sheet <NUM>. In some embodiments, the edge seal <NUM> can extend from an inner corner where the second portion <NUM> meets the third portion <NUM> to the front sheet <NUM> and adhesive layers <NUM>, <NUM>, and to an end of the curved portion <NUM>. The edge seal <NUM> can be placed in similar voids formed between the second rail <NUM> and corresponding portions of the photovoltaic apparatus <NUM>.

The back sheet <NUM> further includes a fourth portion <NUM> in the second leg <NUM>, and a fifth portion <NUM> (second folded portion) extending from the base 408E of the second leg <NUM>. An interior angle between the second leg <NUM> and the fifth portion <NUM> of the back sheet <NUM> can be less than <NUM> degrees. The back sheet <NUM> further includes a second curved portion <NUM> extending from the fourth portion <NUM> back towards the front sheet <NUM>. The second curved portion <NUM> can be used to apply a pressure against the front sheet <NUM>, such as applying pressure against the third portion <NUM> of the front sheet <NUM>. In some embodiments, the second curved portion <NUM> can contact the front sheet <NUM>, such as contact the third portion <NUM> of the front sheet <NUM>. The third portion <NUM> of the front sheet <NUM> can be disposed in a space formed between the fourth portion <NUM> of the back sheet <NUM> and the fifth portion <NUM> of the back sheet <NUM> allowing the third portion <NUM> of the front sheet <NUM> to be compressed between the fourth portion <NUM> of the back sheet <NUM> and the fifth portion <NUM> of the back sheet <NUM>.

One or more of the photovoltaic devices <NUM> is disposed at least in the intermediate first portion <NUM> between the first portion <NUM> of the front sheet <NUM> and the first portion <NUM> of the back sheet <NUM>. Furthermore, one or more of the photovoltaic devices <NUM> can be disposed between the second portion <NUM> of the front sheet <NUM> and second portion <NUM> of the back sheet <NUM>. Similarly, one or more of the photovoltaic devices <NUM> can be disposed between the third portion <NUM> of the front sheet <NUM> and the fourth portion <NUM> of the back sheet <NUM>. Additionally, one or more of the photovoltaic devices <NUM> can be disposed between the third portion <NUM> of the back sheet <NUM> and the second portion <NUM> of the back sheet <NUM> allowing the first curved portion <NUM> to compress regions of the laminated structure of the photovoltaic apparatus <NUM> that include one or more of the photovoltaic devices <NUM>, which can help prevent delamination in these regions. Similarly, one or more of the photovoltaic devices <NUM> can be disposed between the fifth portion <NUM> of the back sheet <NUM> and the fourth portion <NUM> of the back sheet <NUM> allowing the second curved portion <NUM> to compress regions of the laminated structure of the photovoltaic apparatus <NUM> that include one or more of the photovoltaic devices <NUM>, which can help prevent delamination in these regions.

<FIG> is a side view of a photovoltaic assembly <NUM>, according to one embodiment. <FIG> is a close-up side view of a supporting beam <NUM> included in the photovoltaic assembly <NUM>, according to one embodiment. The photovoltaic assembly <NUM> includes a first photovoltaic apparatus <NUM>-<NUM> and a second photovoltaic apparatus <NUM>-<NUM>. The photovoltaic assembly <NUM> further includes a first supporting beam <NUM>-<NUM>, a second supporting beam <NUM>-<NUM>, and a third supporting beam <NUM>-<NUM>. In some embodiments, each supporting beam <NUM> can be an I-beam. Each supporting beam <NUM> includes a first supporting channel <NUM> and a second supporting channel <NUM>. Each supporting channel <NUM>, <NUM> (<FIG>) includes a first member <NUM>, a second member <NUM> opposing the first member <NUM>, and a connecting member <NUM> joining the first member <NUM> to the second member <NUM>. In the embodiment shown, the first member <NUM> and the second member <NUM> can each be substantially at a right angle with respect to the connecting member <NUM>. However, in other embodiments, the first member <NUM> and the second member <NUM> can each be at angles other than right angles with respect to the connecting member <NUM>. Furthermore, in some embodiments one curved member can form the respective channels <NUM>, <NUM>.

The rails <NUM>, <NUM> of each photovoltaic apparatus <NUM>-<NUM>, <NUM>-<NUM> can be fitted into the channels <NUM>, <NUM> of the beams <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM>. For example, the first rail <NUM> of the first photovoltaic apparatus <NUM>-<NUM> can be placed in the second supporting channel <NUM> of the first supporting beam <NUM>-<NUM>, and the second rail <NUM> of the first photovoltaic apparatus <NUM>-<NUM> can be placed in the first supporting channel <NUM> of the second supporting beam <NUM>-<NUM>. Similarly, the first rail <NUM> of the second photovoltaic apparatus <NUM>-<NUM> can be placed in the second supporting channel <NUM> of the second supporting beam <NUM>-<NUM>, and the second rail <NUM> of the second photovoltaic apparatus <NUM>-<NUM> can be placed in the first supporting channel <NUM> of the third supporting beam <NUM>-<NUM>.

The rails <NUM>, <NUM> including the third portion <NUM> and fifth portion <NUM> and the respective curved portions <NUM>, <NUM> of the back sheet <NUM> are deformable to enable the rails <NUM>, <NUM> to tightly fit within the corresponding channels <NUM>, <NUM>. For example for the first rail <NUM>, this tight fit enables the third portion <NUM> and the curved portion <NUM> of the back sheet <NUM> to apply a pressure back on the front sheet <NUM> of the photovoltaic apparatus <NUM>. Furthermore, the supporting channels <NUM>, <NUM> can each include respective angled surfaces <NUM>, <NUM> that portions of the front sheet <NUM> can contact when the photovoltaic apparatus <NUM> is placed in the supporting channels <NUM>, <NUM> of the respective supporting beam <NUM>. In some embodiments, the busbars <NUM>, <NUM> are disposed at locations underlying the portions of the front sheet <NUM> which contacts the respective angled surfaces <NUM>, <NUM> to enable the respective angled surfaces <NUM>, <NUM> to apply a pressure against the portions of the front sheet <NUM> disposed directly over the busbars <NUM>, <NUM> to help prevent the front sheet <NUM> and the busbars <NUM>, <NUM> from delaminating from the laminated structure of the photovoltaic apparatus <NUM>. In some embodiments, the angled surfaces <NUM>, <NUM> may include a padding material, such as a polymer, rubber, or fabric to help form a seal against the front sheet <NUM> of the respective photovoltaic apparatus <NUM> to prevent dirt or water ingress into the supporting channels <NUM>, <NUM> of the respective supporting beam <NUM>.

Placing the photovoltaic apparatuses <NUM>-<NUM>, <NUM>-<NUM> into the supporting channels <NUM>, <NUM> of the respective supporting beams <NUM> also allows the photovoltaic apparatuses <NUM>-<NUM>, <NUM>-<NUM> to be placed closely together, so that only a minor portion of a supporting surface (e.g., a roof) is not used to generate energy. For example, in some embodiments the second busbar <NUM> of the first photovoltaic apparatus <NUM>-<NUM> is spaced apart from the first busbar <NUM> of the second photovoltaic apparatus <NUM>-<NUM> by a distance <NUM> of from about <NUM> to about <NUM>, such as from about <NUM> to about <NUM>, such as from about <NUM> to about <NUM>. Installation of the photovoltaic assembly <NUM> can be performed very quickly. For example, once the supporting beams are secured in place, the remainder of the mechanical installation only requires positioning the photovoltaic apparatuses <NUM> so that the rails <NUM>, <NUM> fit inside the supporting channels <NUM>, <NUM> of the supporting beams <NUM>. The simplicity of this mechanical installation reduces the overall costs of installing the photovoltaic system and increases the cost-competitiveness of the photovoltaic system relative to alternatives.

<FIG> is a partial side cross sectional view of a photovoltaic apparatus <NUM>, according to one embodiment. The view shown in <FIG> is similar to the view shown on the left-hand side of <FIG> of the photovoltaic apparatus <NUM>. The photovoltaic apparatus <NUM> is similar to the photovoltaic apparatus <NUM> except that the first leg <NUM> of the photovoltaic apparatus <NUM> is replaced with a first leg <NUM> in the photovoltaic apparatus <NUM>, the first rail <NUM> of the photovoltaic apparatus <NUM> is replaced with a first rail <NUM> in the photovoltaic apparatus <NUM>, and the back sheet <NUM> of the photovoltaic apparatus <NUM> is replaced with a back sheet <NUM> of the photovoltaic apparatus <NUM>. The back sheet <NUM> of the photovoltaic apparatus <NUM> includes a first portion <NUM> in the intermediate first portion <NUM>, a second portion <NUM> in the first leg <NUM>, and a third portion <NUM> (first folded portion) extending from a base 417E of the first leg <NUM>. The first leg <NUM> of the photovoltaic apparatus <NUM> includes a first busbar <NUM>-<NUM> that is disposed at a different position from the first busbar <NUM> of the photovoltaic apparatus <NUM>. For example, the first busbar <NUM>-<NUM> is disposed between locations of the front sheet <NUM> and the back sheet <NUM>, which are substantially flat as opposed to being disposed between the curved portions of the front sheet <NUM> and the back sheet <NUM> in the photovoltaic apparatus <NUM>.

Furthermore, the back sheet <NUM> includes a curved portion <NUM> extending from the third portion <NUM> towards the front sheet <NUM>. In the photovoltaic apparatus <NUM>, the curved portion <NUM> extends towards an edge <NUM> of the front sheet <NUM> and to a portion of the front sheet <NUM> directly overlying the first busbar <NUM>-<NUM>, so that the curved portion <NUM> can apply a pressure to the edge <NUM> of the front sheet <NUM> and to the first busbar <NUM>-<NUM> to help prevent the edge <NUM> of the front sheet <NUM> and the first busbar <NUM>-<NUM> from delaminating from the laminated structure of the photovoltaic apparatus <NUM>. The edge seal <NUM> can be disposed between the curved portion <NUM> and the front sheet <NUM> in order to distribute the force from curved portion <NUM> over a larger area of the front sheet <NUM>.

<FIG> is a side view of a photovoltaic assembly <NUM>, according to one embodiment. The photovoltaic assembly <NUM> is similar to the photovoltaic assembly <NUM> described above in reference to <FIG> except that the photovoltaic assembly <NUM> includes photovoltaic apparatuses <NUM>-<NUM>, <NUM>-<NUM> instead of the photovoltaic apparatuses <NUM>-<NUM>, <NUM>-<NUM>, and includes supporting beams <NUM> instead of the supporting beams <NUM> described above. The supporting beams <NUM> are similar to the supporting beams <NUM> described above except that the connecting member <NUM> is shorter in the Z-direction than the connecting member <NUM>, the first member <NUM> shorter in the Y-direction than the first member <NUM>, and the second member <NUM> is longer in the Y-direction than the second member <NUM>. Furthermore, the photovoltaic assembly <NUM> includes an inter-module cover <NUM> disposed on the first member <NUM> of the supporting beams <NUM> that are between photovoltaic apparatuses <NUM>. The inter-module cover <NUM> may be flush with the front sheets <NUM> of the photovoltaic apparatuses <NUM>. Furthermore, the inter-module cover <NUM> may form a seal to prevent dirt and water ingress between the photovoltaic apparatuses. In some embodiments, the inter-module cover <NUM> may be bonded to the corresponding supporting beam <NUM> or be an integral part of the corresponding beam <NUM>. Furthermore, in some embodiments, the inter-module cover <NUM> may be formed of a metal, a polymer, a fiber-reinforced composite, and/or a rubber material.

In other embodiments, the shape of the photovoltaic apparatuses and the shape of the supporting channels of the supporting beams may be further modified, so that the front sheets <NUM> of adjacent photovoltaic apparatuses contact each other or approach contacting each other and the inter-module cover <NUM> is not needed, or a smaller inter-module cover can be used. For example, <FIG> shows a side view of a photovoltaic assembly <NUM>, according to such an embodiment. The photovoltaic assembly <NUM> includes a first photovoltaic apparatus <NUM>-<NUM> and a second photovoltaic apparatus <NUM>-<NUM>. The photovoltaic assembly <NUM> further includes a first supporting beam <NUM>-<NUM>, a second supporting beam <NUM>-<NUM>, a third supporting beam <NUM>-<NUM>. The photovoltaic apparatuses <NUM>-<NUM>, <NUM>-<NUM> each include a first rail <NUM> and a second rail <NUM>. The rails <NUM>, <NUM> of the photovoltaic apparatuses <NUM>-<NUM>, <NUM>-<NUM> are placed within the supporting channels of the respective beams <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM> in a similar fashion as described above in reference to the photovoltaic assembly <NUM> shown in <FIG>.

The front sheets <NUM> of the photovoltaic apparatuses <NUM>-<NUM>, <NUM>-<NUM> can contact each other over the second supporting beam <NUM>-<NUM> at a point of contact <NUM>. Thus, the photovoltaic apparatuses <NUM>-<NUM>, <NUM>-<NUM> can each apply pressure to the front sheet <NUM> of the other photovoltaic apparatus at the point of contact <NUM> to assist in preventing delamination of the front sheets <NUM> of the respective photovoltaic apparatuses <NUM>. Furthermore, the second busbar <NUM> of the first photovoltaic apparatus <NUM>-<NUM> and the first busbar <NUM> of the second photovoltaic apparatus <NUM>-<NUM> can directly underlie the portions of the respective front sheet <NUM> that contacts the front sheet <NUM> of the adjacent photovoltaic apparatus <NUM> to assist in preventing delamination of the busbars <NUM>, <NUM> from the laminated structure of the corresponding photovoltaic apparatus <NUM>. Furthermore, because the front sheets <NUM> of the adjacent photovoltaic apparatuses <NUM> contact each other, a higher proportion of the supporting structure (e.g., a roof) can be used to produce photovoltaic energy relative to photovoltaic assemblies where at least some spacing exists between the photovoltaic apparatuses. In some embodiments, a filler <NUM> (e.g., a butyl filler) may be placed between the adjacent photovoltaic apparatuses <NUM> to prevent any ingress of water or dirt between the photovoltaic apparatuses <NUM>.

Furthermore, in some embodiments one or more junction boxes <NUM> similar to the junction box <NUM> described above (<FIG>) may be placed against one or more legs of the photovoltaic apparatuses <NUM>. In some embodiments, the junction box <NUM> may be placed against the back side of the leg, i.e., the leg portion that is part of the concave surface formed by the photovoltaic apparatus <NUM>. In some embodiments, the junction box <NUM> may be placed in the void created between the photovoltaic apparatuses <NUM> below the contact point <NUM>. Placing the junction box <NUM> at these locations allows easy electrical connections between the photovoltaic apparatuses <NUM> and places the junction box in a protected environment beneath the filler <NUM>.

<FIG> is a partial side cross sectional view of a photovoltaic apparatus <NUM>, according to one embodiment. The photovoltaic apparatus <NUM> is similar to the photovoltaic apparatus <NUM> except that the photovoltaic apparatus <NUM> includes a modified back sheet <NUM>-<NUM>. The back sheet <NUM>-<NUM> includes a third portion <NUM> extending outward of the intermediate first portion <NUM> from the base 417E of the first leg <NUM>. The back sheet <NUM>-<NUM> further includes a fourth portion <NUM> extending inward towards the front sheet <NUM> from the third portion <NUM>. The inwardly extending fourth portion <NUM> has an outer surface forming a first slot <NUM>-<NUM> facing away from the front sheet <NUM>. In some embodiments, the slot <NUM>-<NUM> can be substantially in the shape of a semi-circle or some other portion of a circle or other shape, such as a polygon. The back sheet <NUM>-<NUM> further includes a fifth portion <NUM> extending inwardly towards the front sheet <NUM> from the fourth portion <NUM>. Together, the third portion <NUM>, the fourth portion <NUM>, and the fifth portion <NUM> form a first rail <NUM> of the photovoltaic apparatus <NUM>. The combined shape of the third portion <NUM>, the fourth portion <NUM>, and the fifth portion <NUM> may help prevent the collection of debris or other material within the space formed between the first rail <NUM> and the front sheet <NUM>. The combined shape of the third portion <NUM>, the fourth portion <NUM>, and the fifth portion <NUM> may also allow the material used to form the edge seal <NUM> to be easily positioned and retained within the formed space to further prevent the ingress of environmental contamination near the edge of the photovoltaic assembly.

<FIG> is a side view of a photovoltaic assembly <NUM>, according to one embodiment. The photovoltaic assembly <NUM> includes a first photovoltaic apparatus <NUM>-<NUM> and a second photovoltaic apparatus <NUM>-<NUM>. Each photovoltaic apparatus <NUM> includes a first rail <NUM> (described above) and a second rail <NUM>. The second rail <NUM> can be a mirror image of the <NUM>. Thus, the second rail <NUM> can include a slot <NUM>-<NUM> that is the mirror image of the slot <NUM>-<NUM> described above. The photovoltaic apparatuses <NUM> can be placed adjacent to each other, so that the slots <NUM>-<NUM>, <NUM>-<NUM> are aligned directly next to each other and a cable <NUM> can extend through the slots <NUM>-<NUM>, <NUM>-<NUM>. The cables <NUM> can be secured to a supporting structure (e.g., a roof) and the photovoltaic apparatuses <NUM> can be positioned so that the corresponding slots <NUM> of the photovoltaic apparatuses <NUM> fit around the cables <NUM>, which secures the photovoltaic apparatuses <NUM> in place. The angle 213i shows that the angle of the legs, such as the first leg <NUM>, relative to the intermediate first portion <NUM> is reduced after installation in the photovoltaic assembly <NUM> relative to the angle <NUM> (<FIG>) before installation.

Referring to <FIG>, the slots <NUM> can include an edge <NUM>, where the fourth portion <NUM> meets the third portion <NUM>. The edge <NUM> can act as a catch, so that wind or other disturbances do not remove the photovoltaic apparatuses <NUM> from their installed location that is secured by placing the slots <NUM> around respective cables <NUM>. In some embodiments, a rod, bar or similar object may be used in place of the cable <NUM>. Installation of the photovoltaic assembly <NUM> can be performed very quickly. For example, once the cables <NUM> are secured in place, the remainder of the mechanical installation only requires positioning the photovoltaic apparatuses <NUM> so that the corresponding slots <NUM> of the photovoltaic apparatuses <NUM> fit around the cables <NUM>.

Although the photovoltaic apparatus <NUM> was described as having a first rail <NUM> extending from the first leg <NUM> of photovoltaic apparatus <NUM>, in other embodiments, more than one rail can extend from the first leg <NUM>, such as two or more rails each having a slot for engaging a cable, such as cable <NUM>. Using multiple rails with multiple slots for engaging multiple cables can help distribute the forces encountered by the photovoltaic apparatuses when secured to cables, such as the cable <NUM>. Furthermore, embodiments using cables to secure the photovoltaic apparatuses to the corresponding photovoltaic assembly can also adopt one or more of the beneficial features described above in reference to the embodiments using the supporting beams, such as the embodiments described in reference to <FIG>. For example, an embodiment, using cables to secure the photovoltaic apparatuses to a photovoltaic assembly could also be designed so that the front sheets <NUM> (<FIG>) of adjacent photovoltaic apparatuses could contact each other at point similar to the contact point <NUM> described above in reference to <FIG> to help prevent delamination of the front sheet <NUM> and busbars <NUM>, <NUM> underlying the contact point between the front sheets <NUM>.

<FIG> is a process flow diagram of a method <NUM> for forming the photovoltaic apparatus <NUM> of <FIG>, according to one embodiment. At block <NUM>, the back sheet <NUM> is provided. At block <NUM>, the internal components of the photovoltaic apparatus <NUM> are placed onto the back sheet <NUM>. These internal components can include the back-side adhesive <NUM>, the substrate <NUM>, the photovoltaic device <NUM>, the front-side adhesive <NUM>, and the rovings <NUM>. At block <NUM>, the edge seal <NUM> is placed onto the back sheet <NUM> surrounding the internal components of the photovoltaic apparatus <NUM>. In some embodiments, the edge seal material is placed around areas which will contact the edges of the front sheet <NUM>.

At block <NUM>, the front sheet <NUM> is placed over the internal components of the photovoltaic apparatus <NUM> and the edge seal <NUM> to form a photovoltaic assembly that can include the back sheet <NUM>, the back-side adhesive <NUM>, the substrate <NUM>, the photovoltaic device <NUM>, the front-side adhesive <NUM>, and the edge seal <NUM>. At block <NUM>, the photovoltaic assembly can be laminated.

At block <NUM>, the photovoltaic assembly can be heated before the folding process. In some embodiments, the photovoltaic assembly may be heated to a temperature from about <NUM> to about <NUM>, such as from about <NUM> to about <NUM>. At block <NUM>, the folding process is performed on the photovoltaic assembly to form one or more of the legs <NUM>, <NUM>, and the rails <NUM>, <NUM> of the photovoltaic apparatus <NUM>. Using the back sheet <NUM> (<FIG>) to form the rails <NUM>, <NUM> that are used to secure the photovoltaic apparatuses in the supporting beams <NUM> (<FIG>) greatly simplifies the process of forming the photovoltaic apparatus <NUM> because no extra parts are required to form the rails <NUM>, <NUM> and no extra steps are needed to attach the rails to the photovoltaic apparatus <NUM>.

<FIG> is a process flow diagram of an alternative method <NUM> for forming the photovoltaic apparatus <NUM> of <FIG>, according to one embodiment. At block <NUM>, the back sheet <NUM> is folded at opposing sides of the back sheet <NUM> to give the back sheet <NUM> a shape similar to the shape of the back sheet <NUM> shown in <FIG>. However, in some embodiments only the folds to form the legs <NUM>, <NUM> are performed in this step and the folds to form the rails <NUM>, <NUM> are performed at a later step. Folding the back sheet <NUM> in this way allows for the busbars <NUM>, <NUM> to be placed on areas of the photovoltaic apparatus <NUM> that receive little to no light and increase the proportion of a supporting structure's surface area (e.g., surface area of a roof) that can be used to produce energy when multiple photovoltaic apparatuses are placed next to each other. In some embodiments, a plate bending roller assembly can be used to create the folds and the back sheet <NUM>. At block <NUM>, a back sheet adhesive can optionally be placed on the back sheet <NUM>.

At block <NUM>, if the rails <NUM>, <NUM> were formed during block <NUM>, then the rails <NUM>, <NUM> can be pried opened. At block <NUM>, the photovoltaic assembly including the back-side adhesive <NUM>, the substrate <NUM>, the photovoltaic device <NUM>, the front-side adhesive <NUM>, the front sheet <NUM>, and the edge seal <NUM> can be placed on the back sheet adhesive that was optionally added in block <NUM>. However, in some embodiments the photovoltaic assembly can be placed directly on the back sheet <NUM> if the back sheet adhesive is not used. At block <NUM>, the photovoltaic apparatus <NUM> is optionally heated to improve adhesion between the photovoltaic assembly and the back sheet <NUM>. A laminator adapted to process curved plates can be used to heat the photovoltaic apparatus <NUM> during block <NUM>. The heat provided at block <NUM> can melt or partially melt one or more of the layers, such as the adhesive layers <NUM>, <NUM> or the edge seal <NUM>, to promote adhesion between the different layers in the photovoltaic apparatus <NUM>. At block <NUM>, if the rails <NUM>, <NUM> were not formed during block <NUM>, the back sheet <NUM> can be folded at this point to form the rails <NUM>, <NUM>.

Claim 1:
A photovoltaic apparatus (<NUM>), comprising:
a laminated structure comprising an intermediate first portion (<NUM>) connecting a second portion (<NUM>) including a first leg (<NUM>, <NUM>) having a base (407E) to a third portion (<NUM>) including a second leg (<NUM>);
a front sheet (<NUM>) extending through at least part of each of the intermediate portion (<NUM>), the first leg (<NUM>, <NUM>), and the second leg (<NUM>);
a back sheet (<NUM>, <NUM>) having a first portion (<NUM>), a second portion (<NUM>, <NUM>), and a first folded portion (<NUM>) extending from the base of the first leg (407E), the back sheet (<NUM>, <NUM>) extending through at least part of each of the intermediate first portion (<NUM>), the first leg (<NUM>, <NUM>), and the second leg (<NUM>),
one or more photovoltaic devices (<NUM>) disposed at least in the intermediate portion (<NUM>), wherein each of the one or more photovoltaic devices (<NUM>) includes an array of photovoltaic cells (<NUM>),
characterised in that
an interior region (<NUM>) is formed between the first leg (<NUM>, <NUM>) and the second leg (<NUM>), and the first folded portion (<NUM>) extends outward of the interior region (<NUM>); and
an interior angle is formed between the first leg (<NUM>, <NUM>) and the first folded portion (<NUM>), and is less than <NUM> degrees;
a busbar (<NUM>, <NUM>-<NUM>, <NUM>) is disposed between the first folded portion (<NUM>) of the back sheet (<NUM>, <NUM>) and a portion of the back sheet (<NUM>, <NUM>) in the first leg (<NUM>, <NUM>).