Solar panel frame

Abstract

A solar panel frame and a manufacturing method therefor are disclosed. According to the present disclosure, a solar panel frame comprises: a plurality of frame modules surrounding and supporting corners of the solar panel; and a plurality of corner keys having a pair of arms inserted into respective box areas of adjacent frame modules in order to couple the adjacent frame modules to each other. The frame module has a panel accommodation structure for forming a panel accommodation area, which is a space opened toward the inside of the frame module. The box area and the panel accommodation area are formed by providing a series of bends and folds to a single metal strip in the longitudinal direction of the frame module.

Description

Frame for solar panels

[0001] The present invention relates to solar panel technology, in particular to a frame for a solar panel and a method for manufacturing the same.

[0002] The content described in this section merely provides background information regarding the present invention and does not constitute prior art.

[0003] A solar panel consists of solar cells, glass, encapsulant, backsheet, etc., and a solar frame (simply put, frame) is a structure that supports the corners of the solar panel (typically, the four corners of a rectangular panel) by fitting them in place.

[0004] Since solar panels may be damaged if bending or torsional deformation occurs in the panels due to external forces such as wind or snow load, the frame members must have appropriate strength and rigidity, and a joining method capable of securing appropriate bonding force between the frame members is required. In addition, it must perform its role as a supporting structure without corrosion or deterioration during the service life of the solar panels.

[0005] Various frames have emerged for application in solar panels. However, the manufacturing process of existing frames is complex and costly, and there is a need to improve the quality of the frames. In particular, the extrusion molding method inevitably allows design freedom in only two spatial dimensions, which imposes limitations in meeting the structural requirements of the frames.

[0006] The main purpose of the present disclosure is to provide a frame having a structure that can satisfy structural requirements while increasing the manufacturing efficiency of a photovoltaic frame.

[0007] Another aspect of the present disclosure is to provide a structure and material of frame members that can maintain rigidity and prevent deformation when bending or twisting is induced by external forces.

[0008] Another aspect of the present disclosure is to provide an improved joining method that can improve the joining force between frame members.

[0009] The problems to be solved by the technologies of the present disclosure are not limited to those mentioned above, and other unmentioned problems will be clearly understood by a person skilled in the art from the description below.

[0010] According to one aspect of the present disclosure, a frame for a solar panel is provided, comprising: a plurality of frame modules surrounding and supporting the corners of the solar panel; and a plurality of corner keys each having a pair of arms fitted into the box area of ​​the adjacent frame modules to join the adjacent frame modules together.

[0011] Each frame module includes a bottom support forming the bottom surface of the frame module, a first box edge portion provided on the outer part of the frame module and extending in the height direction from the bottom support, a second box edge portion provided on the inner part of the frame module and extending in the height direction from the bottom support, and a panel support portion extending from the second box edge portion and facing the bottom support.

[0012] The box area into which the arm of the corner key is inserted is formed by being surrounded by a lower support, a first box edge, a second box edge, and a panel support.

[0013] Each frame module further includes a panel receiving structure that is provided at the top of the panel support and forms a panel receiving area, which is a space open toward the inner part of the frame module.

[0014] The lower support, the first box edge, the second box edge, the panel support, and the panel receiving structure are formed by providing a series of bends and folds along the longitudinal direction of the frame module to a single metal strip. In particular, a first branch of the single metal strip extending in the height direction from the panel support and a second branch of the single metal strip extending from the top of the first box edge overlap each other to form the walls and cover of the panel receiving structure.

[0015] In various embodiments, the frame for the solar panel may further include the following features.

[0016] In some embodiments, at the location where the first branch and the second branch of the single metal strip meet, the first branch has a folded structure forming a rounded edge facing the upper part of the first box edge portion, and the second branch has a folded structure forming a glove that accommodates and supports the rounded edge of the first panel support portion.

[0017] In some embodiments, the end of the second branch is configured to cover the end of the first branch with a folding structure forming a rounded edge, and the rounded edge of the second branch is configured to come into contact with the upper surface of the solar panel when the corner of the solar panel is inserted into the panel receiving area (128). The end of the cover of the panel receiving structure is bent downward so that the rounded edge of the second branch can come into contact with the upper surface of the solar panel.

[0018] In some embodiments, the lower support portion in the inner part of the box area has a folded structure that forms a corrugated shape to support the lower part of the second box edge portion from the side.

[0019] In some embodiments, the bottom support has a folding structure to form a rounded edge in the inner part of the frame module, and the bottom support is made of two layers of metal strips until it reaches a bend where the second box edge extends.

[0020] In some embodiments, the corner key is configured such that the arm of the corner key is press-fitted into the box area.

[0021] In some embodiments, the maximum width and maximum height of the arm of the corner key have dimensions equal to or greater than the width and height of the box area, and the end portion of the arm of the corner key is configured such that the width and height decrease as they extend along the length of the arm.

[0022] In some embodiments, the corner key has a structure in which an 'L'-shaped first plate and an 'L'-shaped second plate forming the side walls of a pair of arms are connected by an outer support wall that defines the height of the arm without an inner support wall.

[0023] In some embodiments, the corner key has a structure in which an 'L'-shaped first plate and an 'L'-shaped second plate forming the side walls of a pair of arms are connected by an inner support wall that defines the height of the arms without an outer support wall.

[0024] In some embodiments, the first box edge portion or the second box edge portion has at least one anti-detachment projection formed protruding in a direction toward the interior of the box area, and the corner key has at least one anti-detachment hole formed on the outer surface of the arm, and when the arm of the corner key is inserted into the box area, the anti-detachment projection is inserted into the anti-detachment hole.

[0025] In some embodiments, the first box edge portion or the second box edge portion has one or more anti-detachment holes penetrating into the box area, and the corner key has at least one anti-detachment projection formed on the outer surface of the arm, and when the arm of the corner key is inserted into the box area, the anti-detachment projection is inserted into the anti-detachment hole.

[0026] In some embodiments, both longitudinal ends of the frame module have cut inclined sections so that the sections interlock when adjacent frame modules are joined vertically.

[0027] In some embodiments, the material of the single metal strip is one selected from the group comprising plated or unplated steel, aluminum, and metal alloys.

[0028] According to one aspect of the present disclosure, a method for manufacturing a frame for a solar panel is provided. The manufacturing method comprises the steps of manufacturing a frame module that surrounds and supports the corners of the solar panel, and manufacturing a corner key having a pair of arms that are each fitted into the box regions of the adjacent frame modules to join the adjacent frame modules together.

[0029] The step of manufacturing the frame module includes providing a series of bends and folds along the longitudinal direction of the frame module to a single metal strip to form a panel receiving structure and a box area that provide a panel receiving area, which is a space open toward the inner part of the frame module.

[0030] The above box area is formed by being surrounded by (1) a bottom support forming the bottom surface of the frame module, (2) a first box edge portion provided on the outer part of the frame module and extending in the height direction from the bottom support portion, (3) a second box edge portion provided on the inner part of the frame module and extending in the height direction from the bottom support portion, and (4) a panel support portion extending from the second box edge portion and facing the bottom support portion.

[0031] The first branch of the single metal strip extending in the height direction from the panel support and the second branch of the single metal strip extending from the upper part of the first box edge overlap each other to form the wall and cover of the panel receiving structure.

[0032] The structure of the frame according to the embodiments of the present disclosure is suitable for maintaining rigidity and preventing deformation even when bending or twisting is induced by external forces.

[0033] A frame module, which is one of the frame members according to at least some embodiments of the present disclosure, has a structure suitable for being manufactured by folding from a metal sheet through a roll forming process.

[0034] In at least some embodiments of the present disclosure, the method of joining frame members employed in the frame facilitates assembly between frame members and makes it difficult for the assembled frame members to be separated, thereby enabling the joint force to be maintained even during transportation of the frame assembly or adjustment of the installation position.

[0035] The effects provided by the technologies of the present disclosure are not limited to those mentioned above, and other unmentioned effects will be clearly understood by a person skilled in the art from the description below.

[0036] FIG. 1a is a plan view of a solar panel frame according to one embodiment of the present disclosure.

[0037] Figure 1b is an exploded view of the panel frame shown in Figure 1a.

[0038] FIG. 1c is a cross-sectional view of a frame module shown along the CC cutting line of FIG. 1b.

[0039] FIG. 1d is a cross-sectional perspective view of a frame module shown along the CC cutting line of FIG. 1b.

[0040] FIG. 2a is a three-dimensional view showing various aspects of an anti-detachment projection to be formed on the second box edge portion of a frame module according to one embodiment of the present disclosure.

[0041] FIG. 2b is a cross-sectional view showing a cross-section parallel to the lower support portion of the anti-detachment projection.

[0042] FIG. 3 is a cross-sectional view showing various aspects of a plurality of anti-detachment protrusions that can be formed on a frame module according to one embodiment of the present disclosure.

[0043] FIGS. 4a, FIGS. 4b, FIGS. 4c, and FIGS. 4d are conceptual diagrams showing various embodiments of a corner key having a detachment prevention hole or a detachment prevention projection.

[0044] FIGS. 5A and FIGS. 5B are conceptual diagrams showing how the frame module and the corner key are combined.

[0045] FIGS. 6a, FIGS. 6b, and FIGS. 6c respectively illustrate a perspective view, a front view, and a side view of an exemplary corner key according to one embodiment of the present disclosure.

[0046] Hereinafter, embodiments of the present invention will be described in detail with reference to exemplary drawings.

[0047] It should be noted that when assigning reference numerals to the components of each drawing, the same components are assigned the same reference numeral whenever possible, even if they are shown in different drawings. Furthermore, in describing the embodiments of the present invention, if it is determined that a detailed description of related known components or functions would hinder understanding of the embodiments of the present invention, such detailed description is omitted.

[0048] In addition, terms such as first, second, A, B, (a), (b), etc., may be used when describing the components of the embodiments of the present invention. These terms are intended only to distinguish the components from other components, and the essence, order, or sequence of the components is not limited by the terms. Where it is stated that a component is "connected," "combined," or "connected" to another component, it should be understood that the component may be directly connected or connected to the other component, but that another component may also be "connected," "combined," or "connected" between each component.

[0049] Unless otherwise stated, it should be noted that the description of any one embodiment may also apply to other embodiments.

[0050] FIG. 1a is a plan view of a solar panel frame according to one embodiment of the present disclosure. FIG. 1b is an exploded view of the panel frame shown in FIG. 1a. FIG. 1c is a cross-sectional view of a frame module shown along the CC cutting line of FIG. 1b. FIG. 1d is a cross-sectional perspective view of a frame module shown along the CC cutting line of FIG. 1b.

[0051] Referring to FIG. 1a and FIG. 1b, a panel frame according to one embodiment of the present disclosure includes frame modules (10; 10-1, 10-2, 10-3, 10-4) that surround and support the corners of a solar panel (30), and corner keys (20; 20-1, 20-2, 20-3, 20-4) that connect adjacent frame modules (10). For example, when the solar panel (30) has a rectangular shape, the panel frame may include a first frame module (10-1) corresponding to a first corner of the solar panel (30), a second frame module (10-2) corresponding to a second corner of the solar panel, a third frame module (10-3) corresponding to a third corner of the solar panel (30), a fourth frame module (10-4) corresponding to a fourth corner of the solar panel (30), and four corner keys (20-1, 20-2, 20-3, 20-4) which are corner connecting members that combine a pair of adjacent frame modules (10).

[0052] In the inner part of each frame module (10), a panel receiving area (128), which is a space open toward the panel (30), is formed along the longitudinal direction, and the panel (30) can be received in the panel receiving area (128). Here, the inner part of the frame module (10) is close to the center of the panel (30), and the outer part of the frame module (10) is relatively farther from the center of the panel (30).

[0053] Inside each frame module (10), a box area, which is a closed space along the longitudinal direction, is formed. The corner key is an 'L'-shaped member equipped with a pair of arms, and the pair of arms are each fitted into and joined to the box areas of a pair of adjacent frame modules (10). Both longitudinal ends of the frame module (10) may have inclined sections cut at an angle of approximately 30 to 45 degrees. The inclined sections cut at 45 degrees allow the end sections to interlock precisely with each other when adjacent frame modules (10) are joined vertically.

[0054] A frame module (10) according to one embodiment of the present disclosure may be a single metal strip that is cut, bent, and folded into a desired shape through a roll forming process.

[0055] Referring to FIG. 1c, the bottom support (121) generally represents the bottom of the frame module (10) or panel frame. A first box edge (122) extending vertically from the bottom support (121) is provided on the outer part of the frame module (10). A second box edge (123) extending vertically from the bottom support (121) is provided on the inner part of the frame module (10) (relatively inward compared to the first box edge (122)).

[0056] The frame module (10) includes a bottom support (121), a first box edge (122), a second box edge (123), a panel support (124), and a series of longitudinal bends forming a box area (127) enclosed by these. The intersection of the bottom support (121) and the first box edge (122) is defined by the longitudinal bend. The intersection of the bottom support (121) and the second box edge (123) is defined by the longitudinal bend. The intersection of the second box edge (123) and the panel support (124) is defined by the longitudinal bend. The height (h) of the box area is defined by the gap between the bottom support (121) and the panel support, and the width (w) of the box area is defined by the gap between the first box edge (122) and the second box edge (123).

[0057] The frame module (10) further includes a series of longitudinal folds to form a panel receiving structure comprising a panel support (124), a panel edge (125), an upper support (126), and a panel receiving area (128). The panel receiving area (128) is provided above the box area (127). Generally, the upper support (126) may be parallel to the panel support (124). In some embodiments, the upper support (126) may have a greater gap from the panel support (124) towards the end, or vice versa.

[0058] The panel (30) can be received in the panel receiving area (128) and can optionally be secured with an adhesive sealant. Examples of sealants may include curable liquid silicone, urethane, epoxy, resin, or similar materials.

[0059] In the embodiment illustrated in FIG. 1c, parts of the panel edge portion (125), the upper support portion (126), and the lower support portion (121) are illustrated as forming or including two or multiple layers of metal strips. The multiple layers of metal strips provide sufficient rigidity and support to the frame module (10). Several structural features that provide resistance to bending or twisting to the frame module (10) are described below.

[0060] The panel edge portion (125; 125-1, 125-2) and the upper support portion (126; 126-1, 126-2) are formed by overlapping two branches (or may also be referred to as “legs”) of a single metal strip. Referring to FIG. 1c, a first branch (inner metal strip) of a single metal strip extending vertically from the panel support portion (124) and a second branch (outer metal strip) of a single metal strip extending from the top of the first box edge portion (122) are overlapped to form the panel edge portion (125-1, 125-2) and the upper support portion (126-1, 126-2), which function as walls and covers of the panel receiving structure. That is, the panel edge portion (125; 125-1, 125-2) and the upper support portion (126; 126-1, 126-2) are made of two layers of metal strips.

[0061] At the location where the first branch and the second branch of a single metal strip meet (or separate), the first branch (inner metal strip; 125-2) has a folding structure to form a rounded edge facing the upper part of the first box edge portion (122). The second branch (outer metal strip; 125-1) has a folding structure to form a glove that accommodates and supports the rounded edge of the first panel support portion (124).

[0062] The anti-sagging structure (part labeled 'G' in FIG. 1c) in which the round edge and the glove are combined mitigates or prevents the panel support (124) from sagging downward when a downward load is applied to the panel (30) inserted into the panel receiving area (128). Unlike what is shown in FIG. 1c, if the outer metal strip (125-1) forms the first box edge portion (122) without forming a glove that receives the round edge, the outer metal strip (125-1) may bend sideways when a load is applied to the panel (30), causing the two layers of metal strips to separate from each other and the panel receiving area (128) to sag downward.

[0063] At the end of the upper support (126) facing the center of the panel (30), both ends of the metal strip are hemmed. Referring to the part labeled 'B' in FIG. 1c, the end of the second branch of the metal strip (outer metal strip; 126-1) covers the end of the first branch of the metal strip (inner metal strip; 126-2) with a folded structure forming a rounded edge. The rounded edge of the second branch (126-1) can be configured to come into (almost) contact with the upper surface of the solar panel when the corner of the solar panel (30) is inserted into the panel receiving area (128).

[0064] The height of the panel receiving area (128), defined by the gap between the upper support member (126) and the panel support member (124), may be greater than the thickness of the solar panel (30). When the solar panel (30) is received in the panel receiving area (128), the end of the upper support member (126) may be bent downward, for example, by about 5 to 15 degrees, so that the rounded edge of the upper support member (126) can come into contact with the panel (almost) or press with appropriate force. Since the end of the upper support member (126) that comes into contact with the upper surface of the panel (30) forms a rounded edge, damage to the panel (30) caused by the end of the upper support member (126) can be reduced.

[0065] The second box edge portion (123) is part of the box area (127) and serves to prevent the panel receiving area (128), where the panel (30) is received, from being pushed downward or moving sideways. In particular, a folded structure in the shape of a crease that supports the lower part of the second box edge portion (123) from the side may be formed near the middle part of the lower support portion (121), where the second box edge portion (123) extends in the height direction. This folded structure in the shape of a crease prevents the surface of the second box edge portion (123) from being pushed or bent when subjected to pressure, thereby ensuring the structural stability of the panel receiving structure.

[0066] The end of the lower support member (121) has a folding structure (part labeled 'F' in FIG. 1c) to form a rounded edge in the inner part of the frame module (10), so that the lower support member (121) is made of two layers of metal strips (121-1, 121-2) until the second box edge member (123) extends to the bend. The lower support member (121) may have a plurality of holes formed with the same thickness as one or two layers of metal strips to help fasten the panel assembly to a support structure fixed to the ground or roof.

[0067] Multiple frame modules (10-1, 10-2, 10-3, 10-4) may have bottom support members (121) of the same width. Multiple frame modules (10-1, 10-2, 10-3, 10-4) may have bottom support members (121) of different widths. For example, when the solar panel (30) has a vertically elongated rectangular shape, a pair of frame modules facing each other (e.g., 10-1, 10-3) may have bottom support members (121) of different widths than another pair of frame modules facing each other (e.g., 10-2, 10-4). That is, one frame module (e.g., 10-1) and an adjacent frame module (e.g., 10-2) may have bottom support members (121) of different widths. The wide lower support (121) provides a suitable space for forming and arranging fastening means to ensure load distribution when fastening a panel assembly (i.e., a panel combined with a frame) to a support structure including a rack fixed to the ground or roof. A frame module (10) having a relatively large width may have a shape in which a portion of the longitudinal end of the lower support (121) is cut off.

[0068] The metal strip must have sufficient strength to support the panel (30). The material of the metal strip may be steel (plated or unplated), aluminum, or other metal or metal alloy, etc. In one embodiment, the metal strip may be a plated metal, such as plated steel, which includes a corrosion-resistant plating or treatment having sufficient corrosion resistance. In one embodiment, the metal strip may be galvanized steel or PosMAC® manufactured by POSCO. PosMAC® is a highly corrosion-resistant ternary alloy plated steel sheet of zinc, aluminum, and magnesium, classified into PosMAC 1.5 (Mg 1.5%) and PosMAC 3.0 (Mg 3%) depending on the magnesium content.

[0069] As illustrated in FIGS. 1a and 1b, adjacent frame modules (e.g., 10-1 and 10-4) are joined by fitting arms (21-1, 21-2) of a corner key (20-1), which is a joining member, into a box area (127). Once the arm of the corner key (20) is inserted into the box area (127), an anti-detachment projection and an anti-detachment hole may be formed on at least one inner surface of the box area (127) and at least one outer surface of the corresponding arm of the corner key (20) so that it is difficult to pull it out in the opposite direction. When the arm of the corner key (20) is pressed into the box area (127), the anti-detachment projection may be inserted into the anti-detachment hole.

[0070] In one embodiment, the second box edge portion (123) of the frame module (10) may have one or more anti-detachment protrusions formed protruding in a direction toward the inside of the box area (127), and one or more anti-detachment holes may be formed on the outer surface of the arm of the corner key (20) corresponding thereto. In another embodiment, the first box edge portion (122) of the frame module (10) may have one or more anti-detachment protrusions formed protruding in a direction toward the inside of the box area (127), and one or more anti-detachment holes may be formed on the outer surface of the arm of the corner key (20) corresponding thereto.

[0071] Alternatively, the first box edge portion (122) or the second box edge portion (123) of the frame module (10) may have one or more anti-detachment holes penetrating into the box area (127), and one or more anti-detachment protrusions may be formed on the outer surface of the arm of the corner key (20) corresponding thereto. In some embodiments, one or more anti-detachment protrusions may be formed on the outer surface of the arm of the corner key (20), and one or more anti-detachment holes may be formed on the inner surface of the second box edge portion (123).

[0072] With reference to FIGS. 2 and FIGS. 3, various embodiments of anti-detachment protrusions that can be formed on a frame module are described below. For simplification, it should be noted that other structural features of the frame module described above (e.g., various folding structures, hemmed ends, etc.) in FIGS. 2 and FIGS. 3 have been omitted.

[0073] FIG. 2a is a three-dimensional view showing various aspects of an anti-detachment projection to be formed on the second box edge portion of a frame module according to one embodiment of the present disclosure. FIG. 2b is a cross-sectional view showing a cross-section parallel to the lower support portion (211) of the anti-detachment projection. In FIG. 2a and FIG. 2b, the arrow indicates the direction in which the corner key is inserted into the box area. The cross-section parallel to the lower support portion (211) of the anti-detachment projection may be one of a triangle, a semicircle, a semi-ellipse, or a square.

[0074] In some embodiments, the second box edge portion (213) may include a single anti-detachment projection that is long in the longitudinal direction of the frame module. In other embodiments, the second box edge portion (213) may include a single anti-detachment projection that is long in the height direction of the frame module. In FIGS. 2a and 2b, the anti-detachment projection is illustrated as being formed on the second box edge portion (213), but the anti-detachment projection may also be formed on the first box edge portion (212).

[0075] In some embodiments, a plurality of anti-detachment protrusions may be formed along the length direction of the frame module. In other embodiments, a plurality of anti-detachment protrusions may be formed along the height direction of the frame module. FIG. 2b is a conceptual diagram showing a cross-section parallel to the lower support portion (211) of the anti-detachment protrusion.

[0076] FIG. 3 is a cross-sectional view showing various aspects of a plurality of anti-detachment protrusions that may be formed on a frame module according to one embodiment of the present disclosure. In some embodiments, as illustrated in FIG. 3 (a), the plurality of anti-detachment protrusions may each have a cross-section parallel to the lower support having the same shape. In other embodiments, as illustrated in FIG. 3 (b) and (c), the plurality of anti-detachment protrusions may each have a cross-section parallel to the lower support having a different shape.

[0077] FIGS. 4a, 4b, 4c, and 4d are conceptual diagrams showing various embodiments of a corner key having a non-dislodgement hole or a non-dislodgement projection. Note that the geometry (length, height, width) of the arm of the corner key described below is defined according to the geometry of the box area into which the arm is inserted. For example, the length direction of the arm is the same as the length direction of the box area, and the height direction of the arm is the same as the height direction of the box area.

[0078] Corresponding to at least one anti-detachment projection or anti-detachment hole formed on the inner surface of the box area of ​​the frame module, at least one anti-detachment hole or anti-detachment projection may be formed on the outer surface of the arm of the corner key. In some embodiments, at least one anti-detachment hole may be formed on the outer surface of one arm of the corner key, and an anti-detachment projection may be formed on the outer surface of the other arm.

[0079] FIGS. 4a and FIGS. 4b illustrate a corner key with anti-detachment holes formed in each arm.

[0080] The corner key (410) illustrated in FIG. 4a has a structure in which an 'L'-shaped first plate (411-1) and an 'L'-shaped second plate (411-2) forming the side walls of the arms are connected by an outer support wall (413) that defines the height of the arms (the distance between the side walls) without an inner support wall. The outer support wall (413) has anti-detachment holes (415-1, 415-2) formed therein, which correspond to anti-detachment protrusions formed on the second box edge of the frame module. The cross-section of the arm perpendicular to the longitudinal direction of the arm has a "U" shape. The end of each arm is open.

[0081] The corner key (420) illustrated in FIG. 4b has a structure in which an 'L'-shaped first plate (421-1) and an 'L'-shaped second plate (421-1) forming the side walls of the arms are connected by an inner support wall (423) that defines the height of the arms without an outer support wall. The inner support wall (423) has anti-detachment holes (425-1, 425-2) formed therein. The cross-section of the arm perpendicular to the longitudinal direction of the arm has a "U" shape. The ends of each arm are open.

[0082] FIGS. 4c and FIGS. 4d illustrate a corner key having an anti-detachment projection formed on the outer surface of each arm. The shape of the corner key (430, 440) illustrated in FIGS. 4c and FIGS. 4d is identical to the shape of the corner key (410, 420) illustrated in FIGS. 5a and FIGS. 5b, respectively, except that an anti-detachment projection (435, 445) is formed on the outer surface of each arm instead of an anti-detachment groove.

[0083] The aforementioned descriptions and features regarding anti-detachment protrusions that may be formed on a frame module may be applied to anti-detachment protrusions that may be formed on a corner key. For example, the cross-section perpendicular to the height direction of the anti-detachment protrusion formed on the arm of the corner key may be one of a triangle, a semicircle, a semi-ellipse, or a square. In some embodiments, the corner key may include an anti-detachment protrusion that is long in the length direction of the arm or an anti-detachment protrusion that is long in the height direction of the arm. In some embodiments, a plurality of anti-detachment protrusions may be arranged along the height direction of the arm or along the length direction of the arm. The shapes of the plurality of anti-detachment protrusions may all be identical or different from one another.

[0084] FIGS. 5A and FIGS. 5B are conceptual diagrams showing how the frame module and the corner key are combined.

[0085] The arms of the corner key are fitted into the box area of ​​the frame module. The lengths of a pair of arms of the corner key may be the same or different. The corner key may have a C-shape or other shapes.

[0086] The corner key can be configured so that the arm is press-fitted into the box area formed in the frame module. To this end, the maximum width (w') and / or maximum height (h') of the arm may have dimensions equal to or slightly greater than the internal width (w) and / or height (h) of the box area formed in the frame module. To facilitate the press-fit, the arm of the corner key or the end portion of the arm may be configured so that the width and height decrease as they extend along the length of the arm. Here, the height of the arm is defined by the spacing between the side walls (521-1, 121-2) of the arm, and the width of the arm is defined by the height of the side wall (521). The internal height (h) of the box area is defined by the spacing between the bottom support (511) and the panel support (514), and the width of the box area is defined by the spacing between the first box edge portion (512) and the second box edge portion (513).

[0087] FIGS. 6a, 6b, and 6c respectively illustrate a perspective view, a front view, and a side view of an exemplary corner key according to one embodiment of the present disclosure. The corner key (600) illustrated in FIGS. 6a, 6b, and 6c is based on the basic structure of the corner key (430) illustrated in FIG. 4c, and anti-detachment projections (611-1, 611-2) are formed on each of the arms of the corner key (600). To facilitate interference fitting, the end portion of the arm of the corner key (600) is configured such that the gap between the two side walls (615-1, 615-2) of the arm narrows and the height of the side wall decreases as it moves away from the bending portion where the two arms meet.

[0088] Corner keys can be manufactured through a press process or a die process. The material of the corner key may be the same as or different from that of the frame module. At the bending portion where the two arms of the corner key meet (e.g., 613 in FIG. 6a), a reinforcing plate may be added to reinforce rigidity, or the thickness of the surface forming the bending portion may be formed to be thicker than the thickness of the surface forming the arm, which is advantageous for maintaining the right-angle shape of the corner key against loads or stresses applied to the corner key.

[0089] As described above, the frame module can be manufactured from a metal strip through a roll forming process. The roll forming process can generally be configured as follows: (1) an uncoiler (a device that unwinds a metal strip wound in a coiled state); (2) a feeder (equipment that pushes the strip at regular intervals and flattens the material bent into a circular shape); (3) a press or hydraulic machine (pre-processing equipment that applies hole machining, etc. to the strip); (4) a roll forming machine (equipment that shapes the strip into a desired shape); (5) a cutting system (cutting the strip to a specific length); and (6) a post-processing machine (a machine dedicated to additional processes such as additional holes, notching, bending, and side angle cutting of the product).

[0090] Although the roll forming process is generally performed at room temperature, heat can be generated in the rolls as the metal strip passes between the forming rolls at high speed. This heat not only shortens the lifespan of the roll molds but can also cause the coating on the metal strip to peel off. Therefore, a cutting fluid can be optionally applied to the metal strip to cool it down during the process. The applied cutting fluid can be removed via an air or cleaner process during the final stage of roll forming.

[0091] The foregoing description is merely an illustrative explanation of the technical concept of the present invention, and those skilled in the art to which the present invention pertains will be able to make various modifications and variations within the scope of the essential characteristics of the present invention. Accordingly, the embodiments disclosed in the present invention are intended to explain, not limit, the technical concept of the present invention, and the scope of the technical concept of the present invention is not limited by these embodiments. The scope of protection of the present invention shall be interpreted by the claims below, and all technical concepts within an equivalent scope shall be interpreted as being included within the scope of rights of the present invention.

[0092] 10-1, 10-2, 10-3, 10-4: Frame Module

[0093] 20-1, 20-2, 20-3, 20-4: Corner keys 21-1, 21-2: Arm

[0094] 30: Solar panels

[0095] 121-1, 121-2: Bottom support section 122: First box edge section

[0096] 123: Second box edge 124: Panel support

[0097] 125-1, 125-2: Panel edge portion 1261-1, 126-2: Top support portion

[0098] 127: Box area 128: Panel receiving area

[0099] 214, 224, 234, 435-1, 445-1, 611-1, 611-2: Anti-detachment protrusions

[0100] 415-1, 415-2: Anti-slip groove

Claims

1. As a frame for a solar panel, A plurality of frame modules surrounding and supporting the corners of the above-mentioned solar panel; and It includes a plurality of corner keys having a pair of arms each fitted into the box area of ​​said adjacent frame modules to combine the adjacent frame modules with each other, and Each frame module is, A lower support forming the bottom surface of the above-mentioned frame module; A first box edge portion provided on the outer part of the above frame module and extending in the height direction from the lower support portion; A second box edge portion provided in the inner part of the above frame module and extending in the height direction from the lower support portion; A panel support extending from the second box edge portion and facing the lower support portion; and A panel receiving structure that forms a panel receiving area, which is a space open toward the inner part of the frame module and is provided at the top of the panel support member. Includes, The above box area is formed by being surrounded by the lower support, the first box edge, the second box edge, and the panel support. The lower support portion, the first box edge portion, the second box edge portion, the panel support portion, and the panel receiving structure are formed by providing a series of bending and folding along the longitudinal direction of the frame module to a single metal strip, and A frame for a solar panel, wherein a first branch of the single metal strip extending in the height direction from the panel support portion and a second branch of the single metal strip extending from the upper part of the first box edge portion overlap each other to form a wall and a cover of the panel receiving structure.

2. In Paragraph 1, A frame for a solar panel, characterized in that at the location where the first branch and the second branch of the single metal strip meet, the first branch has a folding structure forming a rounded edge facing the upper part of the first box edge portion, and the second branch has a folding structure forming a glove that accommodates and supports the rounded edge of the first panel support portion.

3. In Paragraph 1, A frame for a solar panel, characterized in that the end of the second branch is configured to cover the end of the first branch with a folding structure forming a rounded edge, and the rounded edge of the second branch is configured to come into contact with the upper surface of the solar panel when the corner of the solar panel is inserted into the panel receiving area.

4. In Paragraph 3, A frame for a solar panel, characterized in that the end portion of the cover of the panel receiving structure is bent downward so that the rounded edge of the second branch can come into contact with the upper surface of the solar panel.

5. In Paragraph 1, A frame for a solar panel, characterized in that the lower support portion in the inner part of the box area has a folded structure forming a corrugated shape that supports the lower part of the second box edge portion from the side.

6. In Paragraph 1, A frame for a solar panel, characterized in that the lower support member has a folding structure to form a rounded edge in the inner part of the frame module, and the lower support member is made of two layers of metal strips until it reaches the bend where the second box edge member extends.

7. In Paragraph 1, A frame for a solar panel, characterized in that the corner key is configured such that the arm of the corner key is press-fitted into the box area.

8. In Paragraph 7, A frame for a solar panel, characterized in that the maximum width and maximum height of the arm of the corner key have dimensions equal to or greater than the width and height of the box area, and the end portion of the arm of the corner key is configured such that the width and height decrease as it extends along the length of the arm.

9. In Paragraph 1, The above corner key is, A frame for a solar panel, characterized in that the 'L'-shaped first plate and the 'L'-shaped second plate forming the side walls of the above pair of arms have a structure in which they are connected by an outer support wall that defines the height of the arm without an inner support wall.

10. In Paragraph 1, The above corner key is, A frame for a solar panel, characterized in that the 'L'-shaped first plate and the 'L'-shaped second plate forming the side walls of the above pair of arms have a structure in which they are connected by an inner support wall that defines the height of the arms without an outer support wall.

11. In Paragraph 1, A frame for a solar panel, characterized in that the first box edge portion or the second box edge portion has at least one anti-detachment projection formed protruding in a direction toward the interior of the box area, the corner key has at least one anti-detachment hole formed on the outer surface of the arm, and when the arm of the corner key is inserted into the box area, the anti-detachment projection is inserted into the anti-detachment hole.

12. In Paragraph 1, A frame for a solar panel, characterized in that the first box edge portion or the second box edge portion has one or more anti-detachment holes penetrating into the box area, the corner key has at least one anti-detachment projection formed on the outer surface of the arm, and when the arm of the corner key is inserted into the box area, the anti-detachment projection is inserted into the anti-detachment hole.

13. In Paragraph 1, A frame for a solar panel, characterized in that the two longitudinal ends of the above-mentioned frame module have cut inclined sections such that the sections interlock with each other when adjacent frame modules are joined vertically.

14. In Paragraph 1, A frame for a solar panel, wherein the material of the single metal strip is one selected from the group comprising plated or unplated steel, aluminum, and metal alloy.

15. A method for manufacturing a frame for a solar panel, A step of manufacturing a frame module that surrounds and supports the corners of the above-mentioned solar panel; and The method includes the step of manufacturing a corner key having a pair of arms that are fitted into the box areas of adjacent frame modules to join adjacent frame modules together. The step of manufacturing the above frame module is, The method includes the step of forming a panel receiving structure and a box area by providing a series of bends and folds along the longitudinal direction of the frame module to a single metal strip, thereby providing a panel receiving area which is a space open toward the inner part of the frame module. The above box area is formed by being surrounded by (1) a bottom support forming the bottom surface of the frame module, (2) a first box edge portion provided on the outer part of the frame module and extending in the height direction from the bottom support portion, (3) a second box edge portion provided on the inner part of the frame module and extending in the height direction from the bottom support portion, and (4) a panel support portion extending from the second box edge portion and facing the bottom support portion. A method for manufacturing a frame for a solar panel, wherein a first branch of the single metal strip extending in the height direction from the panel support portion and a second branch of the single metal strip extending from the upper part of the first box edge portion overlap each other to form a wall and a cover of the panel receiving structure.

16. In Paragraph 15, A method for manufacturing a frame for a solar panel, characterized in that at the location where the first branch and the second branch of the single metal strip meet, the first branch has a folding structure forming a rounded edge facing the upper part of the first box edge portion, and the second branch has a folding structure forming a glove that accommodates and supports the rounded edge of the first panel support portion.

17. In Paragraph 15, A method for manufacturing a frame for a solar panel, characterized in that the end of the second branch of the single metal strip is configured to cover the end of the first branch of the metal strip with a folding structure forming a rounded edge, and the rounded edge of the second branch is configured to come into contact with the upper surface of the solar panel when the corner of the solar panel is inserted into the panel receiving area (128).

18. In Paragraph 17, A method for manufacturing a frame for a solar panel, characterized in that the end portion of the cover of the panel receiving structure is bent downward so that the second branched rounded edge can come into contact with the upper surface of the solar panel.

19. In Paragraph 15, A method for manufacturing a frame for a solar panel, characterized in that the lower support portion in the inner part of the box area has a folded structure forming a corrugated shape that supports the lower part of the second box edge portion from the side.

20. In Paragraph 15, A method for manufacturing a frame for a solar panel, characterized in that the lower support member has a folding structure to form a rounded edge in the inner part of the frame module, and the lower support member is made of two layers of metal strips until it reaches the bend where the second box edge member extends.

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