Lightweight, zero-penetration, pre-formed support molds adapted for rigid thin-film solar modules

With PV modules at current prices, balance of system (BOS) components now control the total installed cost of PV. Lightweight PV systems with minimal roof penetrations allow access to load constrained rooftop markets, particularly in the C&I sector. The US Photovoltaic Manufacturing Consortium (PVMC) in New York is working with various roofing manufacturers, PV module manufacturers, racking manufacturers, and PV installers to develop new and innovative mounting technologies to achieve these goals. One particularly promising technology involves the use of pre-formed composite support molds that adhere directly to membrane roofs, avoiding the need for penetrations into the roof. These products are typically aimed at commercial rooftops with low-slope membrane roofs. PVMC is working with a manufacturer of one of these products in particular to adapt the pre-formed support mold to fit thin-film PV modules. This will help increase its rate of adoption beyond the standard c-Si PV form factor that it caters to today. A 200 kW thin-film PV demonstration array using the support mold is planned following the development activity.