Offset-Layer Photovoltaic Modules for Durable Roof Integration

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Solution Overview

Problem

Existing photovoltaic modules face challenges in optimizing the layout and materials of their encapsulant layers, which can affect efficiency and durability, particularly when installed on roofing structures.

Innovation Solution

The implementation of offset layers composed of thermoplastic polyolefin (TPO) for the encapsulant and glass layers, with specific edge offsets and dimensions, enhances the encapsulation of solar cells and improves module integrity and aesthetics.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If traditional encapsulant layers are used in photovoltaic modules, then the module structure is simple, but the encapsulation efficiency and durability are insufficient

Engineering Contradiction:

Improveencapsulation efficiencyVSAvoidlayer structure

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The backsheet is divided into multiple layers (first backsheet layer, second backsheet layer, third backsheet layer) with distinct functions. Each layer provides specific protection and encapsulation properties, improving overall reliability while distributing structural complexity across specialized components

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent uses composite material structures where different backsheet layers are combined with the encapsulant and solar cells. The first backsheet layer (with first edge offset), second backsheet layer, and third backsheet layer create a composite system that enhances encapsulation efficiency and durability through material synergy

Inventive Principle:

Principle #40Composite materials

2Reliability

If offset layers with different dimensions are implemented, then the encapsulation and durability are improved, but the manufacturing precision requirements increase

Engineering Contradiction:

Improvemodule integrityVSAvoidedge offset alignment

Core Design Contradiction:

ReliabilityVSManufacturing precision

Solution Approach 1:

Different backsheet layers have different edge offset configurations tailored to their specific functions. The first backsheet layer has a first edge offset, the second backsheet layer has a second edge offset, and the third backsheet layer has a third edge offset. This local differentiation optimizes encapsulation at each layer while managing manufacturing precision requirements through functional specialization

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The offset configurations are pre-designed into the backsheet layers during manufacturing. The first edge offset, second edge offset, and third edge offset are established as fixed geometric features before assembly, allowing for standardized manufacturing processes and reducing the precision demands during final module assembly

Inventive Principle:

Principle #10Preliminary action

3Duration of action of stationary object

If multiple backsheet layers with offsets are used, then the durability and encapsulation are enhanced, but the device complexity increases

Engineering Contradiction:

ImprovedurabilityVSAvoidbacksheet layer structure

Core Design Contradiction:

Duration of action of stationary objectVSDevice complexity

Solution Approach 1:

The backsheet is segmented into three distinct layers (first backsheet layer, second backsheet layer, third backsheet layer), each providing specific durability functions. This segmentation allows each layer to be optimized for particular protective roles, enhancing overall durability while organizing complexity into manageable functional units

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The multi-layer backsheet structure creates a composite system where each layer contributes specific durability properties. The combination of first backsheet layer, second backsheet layer, and third backsheet layer with their respective edge offsets forms a composite protective system that enhances long-term durability through material and structural synergy

Inventive Principle:

Principle #40Composite materials

Data Source

PatentUS12414385B2Photovoltaic modules with offset layers

Publication Date: 2025.09.09 GAF ENERGY LLC

AI summary

A system includes a plurality of photovoltaic modules installed on a roof deck. Each of the photovoltaic modules includes solar cells, a first encapsulant encapsulating the solar cells, a frontsheet and a backsheet. The front sheet includes a glass layer. The backsheet includes a first layer and a second layer. Each of the first and second layers includes first, second, third and fourth edges. The first edge of the first layer is offset from the first edge of the second layer, the second edge of the first layer is offset from the second edge of the second layer, the third edge of the first layer is offset from the third edge of the second layer, and the fourth edge of the first layer is offset from the fourth edge of the second layer.