Photovoltaic laminates comprising single polymer composite

Abstract

Photovoltaic (PV) laminates employ a single polymer composite (SPC). The SPCs may be located at various locations of the PV laminate. These locations may include positioning as the entire backsheet of the PV laminate as well as a portion or other layer of the backsheet of the PV laminate. The SPC may be positioned and disposed in the PV laminate so as to reduce tensile and compressive forces generated on PV cells by normal or other live or dead loads experienced by the PV laminate. The SPC may be used to mitigate the weight of a PV laminate and facilitate positioning a PV cell along the neutral axis of the PV laminate.

Description

Background Art

[0001] Photovoltaic (PV) cells, commonly referred to as solar cells, are devices that convert solar radiation into electrical energy. Typically, solar radiation strikes the surface of a solar cell substrate and enters the substrate and generates electron and hole pairs in the bulk of the substrate. The electron and hole pairs migrate to p-doped and n-doped regions in the substrate, creating a voltage difference between the doped regions. The doped regions are connected to conductive regions on the solar cell to conduct current from the cell to an external circuit. When PV cells are combined into an array, such as a PV module, the electrical energy collected from all of the PV cells can be combined in series and parallel arrangements to provide power with a certain voltage and current.

[0002] The PV laminate comprises layers of material, such as PV cells, surrounded by an encapsulant, and positioned between a top layer and a bottom layer of a board surrounding the PV cells and the encapsulant. The top and bottom layers of the board may be made of glass, polymer sheets, composite materials, etc. The top layer of the board is preferably transparent to allow the maximum amount of sunlight to reach the active face of the PV cells. The encapsulant surrounds the PV cells and the top and bottom layers of the board provide a certain amount of environmental protection for the PV cells. The PV laminate is supported at its edges by some kind of support frame, carrying dead loads associated with the weight of the components of the PV laminate as well as live loads from various environmental factors such as wind, snow, and impact projectiles (e.g., hail, plant branches, and windblown debris). BRIEF DESCRIPTION OF THE DRAWINGS

[0003] Figure 1 Shown is a perspective view of a two-dimensional array of PV cells that may be employed in some embodiments.

[0004] Figure 2 Shown is an enlarged portion of a corner of a two-dimensional PV cell array that may be employed in some embodiments.

[0005] Figure 3 A side cross-sectional view illustrating the compressive and tensile forces that a PV laminate may experience under passive or live loading conditions in some embodiments.

[0006] Figure 4 Shown is a side cross-sectional view of a PV laminate that may be employed in some embodiments.

[0007] Figure 5 Shown is a side cross-sectional view of a PV laminate that may be employed in some embodiments.

[0008] Figure 6 Shown is a side cross-sectional view of a PV laminate that may be employed in some embodiments.

[0009] Figure 7Shown is a side cross-sectional view of a PV laminate that may be employed in some embodiments.

[0010] Figure 8 Shown is a perspective view of a single polymer composite material in a multi-layer laminate that may be employed in some embodiments. DETAILED DESCRIPTION

[0011] The following specific embodiments are merely illustrative in nature and are not intended to limit the embodiments of the subject matter of the present application or the use of such embodiments. As used herein, the word "exemplary" means "serving as an example, instance, or illustration". Any embodiment described as exemplary in this article is not necessarily to be construed as being preferred or advantageous over other embodiments. In addition, it is not intended to be bound by any express or implied theory presented in the aforementioned technical field, background technology, summary of the invention, or the following specific embodiments.

[0012] This specification includes references to "one embodiment" or "an embodiment." The appearances of the phrases "in one embodiment" or "in an embodiment" are not necessarily referring to the same embodiment. The particular features, structures, or characteristics may be combined in any suitable manner consistent with the present disclosure.

[0013] Terminology. The following paragraphs provide definitions and / or context for terms that may be found in this disclosure, including the appended claims:

[0014] The term "comprising." is open ended. As used in the appended claims, this term does not exclude additional structures or steps.

[0015] "Configured to." Various units or components may be described or referred to as being "configured to" perform one or more tasks. In such contexts, "configured to" is used to represent structure by indicating that the unit / component includes structure that performs those one or more tasks during operation. Thus, a unit / component may be said to be configured to perform a task even when the specified unit / component is not currently operating (e.g., not turned on / not active). The enumeration of units / circuits / components configured to perform one or more tasks expressly does not intend to invoke 35 U.S.C. §112(f) with respect to the units / components.

[0016] "First," "second," etc. As used herein, these terms are used as labels for the nouns that precede them and do not imply any type of ordering (e.g., spatial, temporal, logical, etc.). For example, reference to a "first" single polymer composite (SPC) backsheet does not necessarily imply that the SPC backsheet is the first backsheet in sequence; rather, the term "first" is used to distinguish the SPC backsheet from another SPC backsheet (e.g., a "second" SPC backsheet).

[0017] "Based on." As used herein, this term is used to describe one or more factors that influence a determination. This term does not exclude additional factors that may influence the determination. That is, the determination may be based only on those factors or at least in part on those factors. Consider the phrase "A is determined based on B." Although B may be a factor that influences the determination of A, this phrase does not exclude that the determination of A is also based on C. In other cases, A may be determined based only on B.

[0018] "Coupled" - The following description refers to elements, nodes or features that are "coupled" together. As used herein, unless expressly stated otherwise, "coupled" means that one element / node / feature is directly or indirectly joined to (or directly or indirectly communicates with) another element / node / feature, and not necessarily mechanically.

[0019] "Inhibit" - As used herein, inhibit is used to describe a reduced or minimized effect. When a component or feature is described as inhibiting an action, movement, or condition, it may completely prevent a result or outcome or a future state altogether. Additionally, "inhibit" may also refer to a reduction or reduction in an outcome, performance, and / or effect that might otherwise occur. Thus, when a component, element, or feature is said to inhibit a result or state, it does not necessarily completely prevent or eliminate the result or state.

[0020] In addition, certain terms may be used in the following description for reference purposes only, and thus these terms are not intended to be limiting. For example, terms such as "upper," "lower," "above," and "below" refer to directions in the drawings to which reference is made. Terms such as "front," "rear," "back," "side," "outer," and "inner" describe directions and / or positions of portions of a component within a consistent but arbitrary framework, which is clearly illustrated by reference to the text and related drawings describing the component in question. Such terms may include the words specifically mentioned above, their derivatives, and words of similar meaning.

[0021] In the following description, many specific details, such as specific operations, are set forth to provide a thorough understanding of the embodiments of the present disclosure. It will be apparent to those skilled in the art that the embodiments of the present disclosure can be implemented without these specific details. In other cases, in order to avoid unnecessarily obscuring the embodiments of the present disclosure, well-known techniques are not described in detail.

[0022] SPC systems can be understood as a combination of single polymer composites in multiple configurations, each of which has different material properties. These different material properties can be produced by processing techniques that are tailored to produce a first configuration of a material having a first set of mechanical properties, and then produce a second configuration of the same material having a second set of mechanical properties. The mechanical properties between the first phase and the second phase may overlap, but there should be some mechanical property differences. An example of an SPC may include a first configuration of polypropylene as a woven fabric and a second configuration of polypropylene as a unidirectional film, wherein the film and the fabric are combined with each other in such a way that they interact and cumulatively act when an active load is applied. SPCs can be considered environmentally friendly composites because they can be easily recycled. For example, when heated above the melting temperature of the SPC, the reinforcement of the SPC and the resin of the SPC both melt together and become the same polymer.

[0023] Various exemplary PV laminates employing one or more partial or complete layers of a single polymer composite are provided herein. By employing such an SPC in a PV laminate, embodiments may improve the live load performance of the PV laminate under one or more of a front live load and a rear live load. In embodiments, the SPC layer may provide a rigid backsheet or other rigid layer of the PV laminate. The rigid backsheet or other rigid layer may help reduce stresses on the PV cells of the PV laminate, and in doing so help reduce cell cracking or other PV cell damage under mechanical live loads. In embodiments, the exterior-facing backsheet or other layer may comprise a single polymer composite (SPC). For example, a rigid backsheet with an SPC may help reduce live loads and other stresses on the PV cells under snow loads or other live loads.

[0024] As described above, an SPC is considered a composite material even though both the reinforcement and the supporting matrix are made of the same polymer. As shown in the tables and text below, in PV laminates, SPCs can be advantageous over thin single-material polymer backsheets because the composite nature of the SPC can provide improved mechanical properties when compared to thin single-material polymer backsheets. As also shown in the tables and text below, employing SPCs in place of glass or heterogeneous composites can result in relatively lightweight PV laminates. In an embodiment, for example, the backsheet layer can be made of a single polymer composite in which both the reinforcement and the resin are made of the same polymer, such as a polyethylene terephthalate (PET) single polymer composite. Other polymers that can be employed can include thermoplastics such as PET, PP, PLA, UHMWPE, and PMMA. In each case, the reinforcement and matrix (binder) of the polymeric SPC are made of the same polymer.

[0025] The SPCs of the embodiments may be positioned at various layers and portions of the PV laminate and may provide resistance to dead loads as well as resistance to static mechanical loads (SML) or other live loads. Such resistance may improve the structural performance of the PV laminate as well as the durability of the PV laminate. For example, in embodiments having an SPC layer, the PV cells of the PV laminate may experience lower stress levels under live loads than PV cells located in the same PV laminate lacking the SPC layer. The use of an SPC layer may also be used to reduce the weight of the PV laminate when compared to a PV laminate that exhibits substantially similar structural performance. In other words, a first PV laminate having an SPC layer may weigh less than a second PV laminate having conventional upper and lower glass layers, but exhibit substantially similar, identical, or improved structural performance under live loads.

[0026] The SPC of the embodiment can be manufactured using various techniques. These techniques can include one or more of the following: hot pressing of fibers; hot pressing of two components; solution impregnation of two components; constrained fiber processing; copolymer method; change of molecular weight; change of chain configuration, etc. In addition, the raw polymers in different physical states and material forms can be used for SPC manufacturing, including melts, solutions, powders, films, tapes, unidirectional plies, chopped fibers and / or fabrics.

[0027] When SPCs are employed in embodiments, similar sized layers in a PV laminate can have lower density and lighter weight when compared to similar sized glass multi-material composite layers. In addition, SPCs can have better mechanical properties than polymer films of the same material, and in doing so can be used to provide improved mechanical load performance for PV laminates and improved strength and durability of the backsheet of the PV laminate. The interfacial adhesion between the reinforcement and the supporting matrix of the SPC can be more durable, stronger, or otherwise preferred when compared to traditional heterogeneous composites. Also, in embodiments, there can be little to no coefficient of thermal expansion (CTE) mismatch between the reinforcement and the supporting matrix of a single polymer composite. For example, the density and weight of a homogenous SPC can be much lower than traditional heterogeneous composites (FR4) and common PV laminate backsheet materials such as PET, PP, and ultra-high molecular weight polyethylene (UHMWPE).

[0028] In an embodiment, SPC can be used to replace PET backsheet (glass-PET backsheet) in monofacial solar cell modules to improve snow load performance. SPC can also be used to replace FR4 (heterogeneous composite material) in flexible solar modules (e.g., the front sheet is a transparent polymer sheet and the back sheet is FR4). SPC can be lighter than FR4, but can have similar mechanical properties.

[0029] In embodiments, the SPC layer can be thinner than the glass layer of the PV laminate. In addition, the SPC can weigh less than the glass layer and also better protect the PV cells of the PV laminate from cracking under load. The PV cells of embodiments can be positioned along the neutral axis of the PV laminate. The neutral axis can be considered to be a reference plane in the PV laminate where the internal tensile and compressive forces reach near zero or zero when considering the normal load of the PV laminate. The SPC employed in embodiments can have various densities, including 1.2-1.5 g / cm 3 Because the density of SPC can be less than the density of glass in embodiments, the weight of the SPC layer in the PV laminate can be less than the weight of the glass layer.

[0030] While in embodiments a full SPC layer may be employed, i.e., the SPC layer extends beneath the entire PV cell array of the PV laminate, some SPC layers in embodiments may not be so sized. In other words, in embodiments, some SPC layers may extend beneath only a portion of the PV cell array. In doing so, different deflection / stiffness characteristics may be produced for the PV laminate in different sections of the PV laminate. In sections of the PV laminate with SPC, the stiffness of the PV laminate will be greater than the stiffness of sections of the PV laminate without SPC. These areas of greater stiffness may be used on sections of the PV laminate where the forces under live or dead loads may be greater than other portions of the PV laminate where the live and dead loads may be less. For example, in a perimeter supported PV laminate, a central section of the PV laminate may have an SPC backsheet support, while the edges of an edge supported PV laminate may have less or no SPC backsheet. Similarly, the SPC backsheet may have a varying thickness or a uniform thickness along its layers. The thickness of the SPC can be set according to the support system of the PV laminate, where areas where higher stress is expected to receive thicker SPC materials, while areas where lower stress is expected to receive thinner SPC materials. In doing so, the weight of the PV laminate can be further reduced while seeking to maintain a minimum amount of protection for the PV cells of the PV laminate. The SPC thickness can range from about 0.2 mm to about 10 mm thick, preferably 0.5 mm-4.0 mm. Other values ​​may also be possible.

[0031] Some embodiments may include one or more glass layers above the PV cell array and one or more SPC bottom layers below the PV cell array. Some embodiments may include glass layers above and below the PV cell array while also having SPC above and below the PV array layer. Other combinations of SPC and glass may also be used in embodiments.

[0032] The photovoltaic laminate of an embodiment may include an array of photovoltaic cells, wherein each photovoltaic cell has a sunlight receiving surface, a bottom surface, and may be electrically connected to one or more photovoltaic cells in the array. The PV laminate may also include: a sealant, the sealant is in contact with at least the sunlight receiving surface or the bottom surface of the photovoltaic cells in the array; a transparent layer, the transparent layer is positioned above the array; and a single polymer composite material, the single polymer composite material is positioned below the array, the single polymer composite material comprising a binder of a first polymer and a reinforcement of the first polymer.

[0033] In some PV laminate embodiments, the single polymer composite may consist essentially of a matrix of a first polymer and a reinforcement of a polymer. In some PV laminate embodiments, an array of photovoltaic cells may include a perimeter, wherein an encapsulant surrounds the array of photovoltaic cells, and wherein the single polymer composite may be planar and may extend to the perimeter of the array of photovoltaic cells. In some PV laminate embodiments, an array of photovoltaic cells may include a perimeter and a perimeter edge, wherein an encapsulant surrounds each photovoltaic cell in the array of photovoltaic cells, and wherein the single polymer composite is planar and extends beyond the perimeter edge of the array of photovoltaic cells.

[0034] Still further, in some PV laminate embodiments, the glass may include a transparent layer and the photovoltaic laminate may have a neutral axis under a top distributed live load, wherein the photovoltaic cell array may be positioned along the neutral axis. In some embodiments, the photovoltaic cell array may be a two-dimensional array, and the single polymer composite may include polyethylene terephthalate (PET). Also, in some PV laminate embodiments, the tensile modulus of the single polymer composite employed may be in the range of 5-300 MPa, and the tensile strength may be in the range of 90 MPa-3 GPa.

[0035] The photovoltaic laminate of an embodiment may include: a glass layer; a first sealant layer, the first sealant layer being positioned below the glass layer; a photovoltaic cell layer, the photovoltaic cell layer being positioned below the first sealant layer; a second sealant layer, the second sealant layer being positioned below the photovoltaic cell layer; and a single polymer composite layer, the single polymer composite comprising a binder of a first polymer and a reinforcement of the first polymer, the polymer composite layer being positioned below the glass layer. In some PV laminate embodiments, the first sealant layer and the second sealant layer may be connected to each other by a sealant material, such as a resin of a sealant. In some PV laminate embodiments, the photovoltaic cell layer may include an array of independent photovoltaic cells, and the first sealant layer and the second sealant layer may be connected to each other by a sealant and may completely surround each independent photovoltaic cell in the photovoltaic cell array. In some PV laminate embodiments, a backsheet layer, such as PET, may be used and does not include a single polymer composite and may be in contact with or spaced apart from the single polymer composite layer. In some PV laminate embodiments, the backsheet layer is the outermost layer of the photovoltaic laminate and comprises polyethylene terephthalate (PET), while in other embodiments, the backsheet layer comprises a polymer and is not the outermost layer of the photovoltaic laminate. In some PV laminates, the photovoltaic cell layer can be planar and can be positioned at the neutral axis of the PV laminate.

[0036] In some PV laminate embodiments, the plurality of photovoltaic cells may include: a plurality of photovoltaic cells having a perimeter; a sealant surrounding the plurality of photovoltaic cells and extending beyond the perimeter; a planar transparent layer positioned above the sealant and extending beyond the perimeter; and a single polymer composite planar layer, the single polymer composite comprising a binder of a first polymer and a reinforcement of the first polymer, the polymer composite layer positioned below the sealant. In some PV laminate embodiments, the single polymer composite planar layer may extend beyond the perimeter of the plurality of PV cells. In some embodiments, there may be a planar backsheet layer in contact with the single polymer composite planar layer. In some embodiments, the first polymer used as the SPC may be selected from the group consisting of: polyethylene terephthalate (PET), polypropylene (PP), and ultra-high molecular weight polyethylene (UHMWPE). In some embodiments, the SPC may include UHMWPE or PP.

[0037] Figure 1 A perspective view of a two-dimensional array of PV cells mounted on a backplane that may be employed in some embodiments is shown. Figure 1 Labeled in FIG. 1 are a PV array 100 , a backsheet perimeter edge 102 of the PV array 100 , PV cells 110 , a module-level power electronics module 104 , and connecting wires 106 . Figure 2 Shown is an enlarged portion of a corner of a two-dimensional PV cell array that may be employed in some embodiments. Figure 2 Labeled in FIG. 1 are the PV connection lines 208 along with the PV array 100 and PV cells 110 and the peripheral edge 102 of the backsheet 103 .

[0038] The PV array 100 is shown as a two-dimensional array, i.e., having multiple rows of strings. Single-string PV arrays, i.e., one row of strings and other configurations of PV arrays may also be employed in embodiments. In embodiments, the PV array 100 may be positioned as a layer of a multi-layer PV laminate. These multiple layers may be configured and positioned to buffer and protect the PV array from environmental influences. These may include live loads on the face of the PV laminate as well as corrosion and other harmful effects of the environment. Embodiments may be configured to reduce the amount and intensity of mechanical stresses imposed on the PV array and its individual cells and connecting wires in order to extend the life and / or effectiveness of the PV array during its lifetime. In embodiments, by placing layers above and below the PV array, mechanical stresses on the PV cells and other components of the PV array may be reduced or eliminated. By using SPC as a complete or partial layer, support may be provided for the PV array. The SPC layer (whether complete or partial) may also reduce weight when compared to heavier materials such as glass layers. When installed, the PV array may be mounted on the same reference plane and in a layered or shingled pattern with overlapping edges, such as an asphalt shingle or cedar shingle roof installation. Other mounting configurations of the PV array may also be possible.

[0039] Figure 3 A side cross-sectional view showing the compressive and tensile forces that a PV laminate may experience under passive or live load conditions in some embodiments. The PV array in an embodiment may be positioned along a neutral axis with one or more layers above and below the PV array to position the PV array at the neutral axis. Figure 3 As can be seen in FIG. 3 , the compressive and tensile forces are larger near the surface and approach or reach zero at the neutral axis. Figure 3 are marked in order to understand how deflections and resulting stresses can be formed.

[0040] Figure 4 Shown is a side cross-sectional view of a PV laminate 400 that may be employed in some embodiments. Figure 4 Labeled in are the glass layer 410, the encapsulant 420, the PV array 100, and the single polymer composite material. As can be seen, the encapsulant surrounds the PV array 100 and there is a glass top sheet and an SPC back sheet. Figure 4Each of the protective layers of the PV laminate in the embodiment of the present invention extends to the peripheral edge of the PV laminate 400. In some embodiments, one or more layers may not be such a complete layer, but may only occupy a portion of the layers of the PV laminate 400. For example, the sealant may not reach the perimeter of the PV laminate, but may only extend through the PV array, with the SPC or other material filling the remaining space of the layer. Figure 4 As can be seen in the figure, the SPC layer is thicker than the glass layer 410. This thicker SPC layer 430 may be used in embodiments to illustrate the physical properties of the SPC when compared to the glass 410. However, even given this thicker layer, the SPC used in embodiments may still have a density lower than the density of glass, and therefore may be lighter in weight even though the SPC may be thicker than the glass layer. In embodiments, the SPC layer may be thinner than the glass layer and may be thicker than the PET backsheet. The SPC thickness may be 0.5mm-4mm. The preferred thickness may be 0.5mm-2mm. The thinner the thickness, the lower the cost.

[0041]

[0042]

[0043] Figure 5 Shown is a side cross-sectional view of a PV laminate that may be employed in some embodiments. Figure 5 Labeled in the figure are glass 410 , sealant 420 , PV array 100 , PET backsheet 540 , and SPC backsheet 430 . Figure 6 Shown is a side cross-sectional view of a PV laminate that may be employed in some embodiments. Figure 6 Labeled in FIG. 4 are glass 410, sealant 420, PV array 100, PET backsheet 540, and SPC backsheet 430. Figure 5 and Figure 6 As can be seen in FIG. 1 , other materials besides SPC may be employed behind the PV array 100, and SPC may or may not be the outermost backsheet employed. Figure 5 In, for example, the PET backsheet is located above the SPC, and in Figure 6 In, for example, the PET backsheet 540 is the outermost layer of the PV laminate 400 .

[0044] Figure 7 Shown is a side cross-sectional view of a PV laminate that may be employed in some embodiments. Figure 7 The transparent polymer front sheet 710, which may include ETFE, PET, etc., the sealant 420, the solar cells 110 and the single polymer composite back sheet 430. Figure 7 It is shown that various materials and sequences of materials may be employed in embodiments.

[0045] Figure 8 Shown is a perspective view of a single polymer composite material 430 in a multi-layer laminate that may be employed in some embodiments. Figure 8 The multilayer laminate has a first layer 850 and a second layer 851. The layers themselves can be SPC as well as different materials. In embodiments, the multilayer laminate can be used with non-layers or additional layers to support a PV array. The layers can have the same perimeter dimensions or can have different perimeter dimensions, such as Figure 8 As shown in the examples. Figure 8 In the embodiments, the layers may have the same, similar, or different thicknesses.

[0046] As described above, various polymers may be employed as SPCs. In one embodiment, the tensile strength of the selected fibers may be one-fold lower than that of glass and carbon fibers, while in other cases, the tensile strength of the selected SPC fibers may be nine-fold lower than that of carbon fibers. However, adhesion characteristics, glass weight, carbon weight, manufacturing flexibility, design flexibility, cost, and other factors may provide advantages of using SPCs over glass and carbon reinforcements. Table A provides exemplary ranges of tensile strength, density, and tensile modulus for various SPC materials as well as non-SPC materials (i.e., glass and carbon fibers).

[0047] Table A - Types and mechanical properties of polymer fibers that can be used as SPC and other non-SPC reinforcement fibers.

[0048]

[0049] Table B provides a comparison of four SPC backsheet materials with two non-SPC backsheet materials. As can be seen in Table B, the tensile strength of each SPC is greater than the tensile strength of the two non-SPCs (i.e., FR4 and PET sheets). It can also be seen that SPCs are generally less dense, but this is not the case in every case.

[0050] Table B - SPC and non-SPC material properties

[0051] <![CDATA[Density, g / cm 3 > Tensile strength, MPa Tensile modulus, GPa 25% filled PET / PET SPC 1.38 94 not applicable PP / PP SPC 0.732 450 15 UHMWPE fiber / HDPE SPC 0.96 600 20 UHMWPE SPC 0.96 1300-1500 (longitude) not applicable FR4 (glass fiber / epoxy resin composite material) 1.85 262 24 PET board 1.38 55 2.7

[0052] In some embodiments, the tensile modulus of the SPC layer can be improved by a range of 5-300 MPa compared to the tensile modulus of a thin PET non-SPC layer, and the tensile strength can be improved by a range of 90 MPa-3 GPa compared to a thin PET non-SPC layer.

[0053] Although specific embodiments have been described above, these embodiments are not intended to limit the scope of the present disclosure, even in the case where only a single embodiment is described with respect to a particular feature. Unless otherwise stated, the examples of features provided in the present disclosure are intended to be illustrative rather than restrictive. The above description is intended to cover such substitutions, modifications, and equivalents that are obvious to those skilled in the art having the benefit of the present disclosure.

[0054] The scope of the present disclosure includes any feature or combination of features disclosed herein (explicitly or implicitly) or any generalization thereof, whether or not it mitigates any or all of the problems addressed herein. Accordingly, new claims may be formulated during the prosecution of the present application (or an application claiming priority thereto) to any such combination of features. Specifically, with reference to the attached claims, features of the dependent claims may be combined with features of the independent claims, and features of the respective independent claims may be combined in any appropriate manner, and not merely in the specific combinations listed in the attached claims.

Claims

1. A photovoltaic laminate comprising: an array of photovoltaic cells, each of the photovoltaic cells having a sunlight receiving surface and a bottom surface, wherein one or more photovoltaic cells are electrically connected to the array; a sealant, the sealant being in contact with at least the sunlight receiving surface or the bottom surface of at least one photovoltaic cell in the photovoltaic cell array; a transparent layer positioned above the photovoltaic cell array; and A single polymer composite is positioned below the array, the single polymer composite comprising a binder of a first polymer and a reinforcement of the first polymer.

2. The photovoltaic laminate of claim 1, wherein the single polymer composite consists essentially of a matrix of the first polymer and the reinforcement of the first polymer.

3. The photovoltaic laminate of claim 1, wherein the photovoltaic cell array further comprises a perimeter, wherein the encapsulant surrounds the photovoltaic cell array, and wherein the single polymer composite is planar and extends to the perimeter of the photovoltaic cell array.

4. The photovoltaic laminate of claim 1 , wherein the photovoltaic cell array further comprises a perimeter and a perimeter edge, wherein the sealant surrounds each photovoltaic cell in the photovoltaic cell array, and wherein the single polymer composite is planar and extends beyond the perimeter edge of the photovoltaic cell array.

5. The photovoltaic laminate of claim 1, wherein the transparent layer is one or more of glass or a transparent polymer sheet, and wherein the photovoltaic laminate has a neutral axis under a top distributed live load, the photovoltaic cell array being positioned along the neutral axis.

6. The photovoltaic laminate of claim 1, wherein the single polymer composite comprises polyethylene terephthalate (PET).

7. The photovoltaic laminate of claim 1, wherein the single polymer composite has a tensile modulus in the range of 5-300 MPa and a tensile strength in the range of 90 MPa-3 GPa.

8. A photovoltaic laminate comprising: Transparent front plate layer; a first sealant layer positioned below the transparent front plate; a photovoltaic cell layer, the photovoltaic cell layer being positioned below the first sealant layer; a second sealant layer positioned below the photovoltaic cell layer; as well as A single polymer composite layer comprising a binder of a first polymer and a reinforcement of the first polymer is positioned below the glass layer.

9. The photovoltaic laminate of claim 8, wherein the first sealant layer and the second sealant layer are connected to each other by a sealant material.

10. The photovoltaic laminate of claim 9, wherein the photovoltaic cell layer comprises an array of individual photovoltaic cells, and wherein the first sealant layer and the second sealant layer are connected to each other by a sealant material and completely surround each individual photovoltaic cell in the photovoltaic cell array.

11. The photovoltaic laminate of claim 8, further comprising a back-sheet layer that does not comprise a single polymer composite material, the back-sheet layer being in contact with the single polymer composite material layer.

12. The photovoltaic laminate of claim 11, wherein the backsheet layer is the outermost layer of the photovoltaic laminate and comprises polyethylene terephthalate (PET).

13. The photovoltaic laminate of claim 11, wherein the backsheet layer comprises a polymer and is not the outermost layer of the photovoltaic laminate.

14. The photovoltaic laminate of claim 8, wherein the photovoltaic laminate has a neutral axis, and the photovoltaic cell layer is planar and positioned at the neutral axis.

15. A photovoltaic laminate comprising: a plurality of photovoltaic cells, the plurality of photovoltaic cells having a perimeter; a sealant surrounding the plurality of photovoltaic cells and extending beyond the perimeter; a planar transparent layer positioned over the sealant and extending beyond the perimeter; as well as A single planar layer of polymer composite material, the single polymer composite material comprising a binder of a first polymer and a reinforcement of the first polymer, the single polymer composite layer being positioned below the sealant.

16. The photovoltaic laminate of claim 15, wherein the single planar layer of polymer composite material extends beyond the perimeter.

17. The photovoltaic laminate of claim 15, further comprising a planar back-sheet layer in contact with the single polymer composite planar layer.

18. The photovoltaic laminate of claim 15, wherein the first polymer is selected from the group consisting of polyethylene terephthalate (PET), polypropylene (PP), and ultra high molecular weight polyethylene (UHMWPE) or a thermoplastic material.

19. The photovoltaic laminate of claim 18, wherein the first polymer is UHMWPE.

20. The photovoltaic laminate of claim 18, wherein the first polymer is PP.

Images