TPO Encapsulant-Backsheet Structure for Fire-Resistant PV Modules
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Solution Overview
Problem
Existing photovoltaic module encapsulation systems often require intervening layers between the encapsulant-backsheet layer and the roof deck, which can compromise the integrity and efficiency of the solar panel installation, particularly in terms of fire resistance and moisture resistance.
Innovation Solution
A photovoltaic module system that integrates a thermoplastic polyolefin (TPO) encapsulant-backsheet layer directly with the roof deck without any intervening layers, utilizing a single extruded, two-ply material with a thickness of 0.2 mm to 4 mm, and including flame retardants and moisture-resistant additives to enhance fire resistance and durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If an intervening layer is used between the encapsulant-backsheet layer and the roof deck, then the installation process is simplified, but the fire resistance and moisture resistance are compromised
Solution Approach 1:
The patent combines the encapsulant and backsheet into a single integrated encapsulant-backsheet layer, eliminating the need for separate intervening layers. This merged structure directly contacts the roof deck while maintaining both fire resistance and moisture resistance properties, resolving the contradiction between installation simplicity and reliability.
Solution Approach 2:
The encapsulant-backsheet layer is constructed as a composite material structure with specific layers designed to provide both fire resistance and moisture resistance. This composite approach allows the single integrated layer to maintain multiple protective functions while simplifying the overall installation process by eliminating the need for additional intervening layers.
2Reliability
If a single extruded encapsulant-backsheet layer is used without intervening layers, then the fire resistance and moisture resistance are improved, but the complexity of material specification increases
Solution Approach 1:
The encapsulant-backsheet layer is designed as a multi-functional universal component that simultaneously provides fire resistance, moisture resistance, and structural encapsulation. This single component performs multiple protective functions that would otherwise require separate layers, reducing material specification complexity while maintaining high reliability.
3Reliability
If the encapsulant-backsheet layer is made from thermoplastic polyolefin, then the moisture resistance is enhanced, but the fire resistance requirements become more challenging to meet
Solution Approach 1:
The patent uses composite material construction within the encapsulant-backsheet layer, combining thermoplastic polyolefin base material with fire-retardant additives and potentially other functional layers. This composite approach maintains the inherent moisture resistance of polyolefin while incorporating fire-retardant properties to meet fire resistance standards.
Solution Approach 2:
The patent modifies the chemical and physical parameters of the thermoplastic polyolefin material by incorporating fire-retardant additives and adjusting material composition. These parameter changes enable the material to maintain its moisture-resistant properties while achieving the required fire resistance performance.
Data Source
AI summary
A system including at least one photovoltaic module configured to be installed on a roof deck having an underlayment layer. The photovoltaic module includes at least one solar cell having a first side and a second side opposite the first side, an encapsulant layer juxtaposed with the first side of the solar cell, a glass layer juxtaposed with the encapsulant layer, and a encapsulant-backsheet layer juxtaposed with the second side of the solar cell. The encapsulant layer and the encapsulant-backsheet layer encapsulate the at least one solar cell. The system does not include an intervening layer between the encapsulant-backsheet layer and the underlayment layer.