Foldable Solar Panel Frame Structure for Lower-Cost Installation

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Solution Overview

Problem

The cost of solar panel frames and their installation remains high due to unchanged frame designs and materials, despite decreasing solar panel costs and improved racking systems.

Innovation Solution

The development of a foldable panel frame made from materials like aluminum or steel, which can be bent to form 90-degree angles, reducing material and manufacturing costs and simplifying installation by creating a stronger, more adaptable frame structure that can be securely attached to racking systems.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If traditional rigid frame designs are used, then structural strength is maintained, but material costs and manufacturing costs remain high

Engineering Contradiction:

Improveframe strengthVSAvoidmanufacturing cost

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

The frame transitions from a rigid, pre-formed structure to a dynamic, foldable structure that can be bent into shape during installation. The elongated frame member is designed to be bent at specific bend areas to form corners, allowing the frame to adapt to different panel configurations while using less material and reducing manufacturing complexity

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The frame design changes the physical state of the frame member from a rigid straight piece to a bent configuration during installation. By introducing bend areas with reduced thickness, the frame can be deformed into angular shapes (e.g., 90-degree corners) to match panel corners, maintaining structural integrity while reducing material usage

Inventive Principle:

Principle #35Parameter changes

2Reliability

If traditional frame designs are used, then structural integrity is maintained, but installation time and labor costs increase

Engineering Contradiction:

Improvestructural integrityVSAvoidinstallation time

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The frame member is pre-designed with integrated bend areas and attachment features during manufacturing. The bend areas are strategically positioned and dimensioned to allow easy folding into corner configurations, and attachment features are pre-positioned for quick connection to racking systems, reducing on-site assembly time while ensuring structural integrity

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The frame is designed as an elongated member with distinct functional segments: straight sections for spanning between corners and bend areas for forming corners. This segmentation allows the frame to be manufactured as a single piece with reduced thickness at bend areas, enabling easy folding and quick installation while maintaining overall structural strength

Inventive Principle:

Principle #1Segmentation

3Ease of manufacture

If foldable frame design is implemented, then material and manufacturing costs decrease, but frame complexity increases

Engineering Contradiction:

Improvemanufacturing costVSAvoidframe structure complexity

Core Design Contradiction:

Ease of manufactureVSDevice complexity

Solution Approach 1:

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The frame member has non-uniform cross-section with reduced thickness specifically at the bend areas while maintaining full thickness in the straight sections. This local variation in material properties allows the frame to be bent easily at corners while retaining structural strength in the spanning sections, reducing overall material usage and cost

Inventive Principle:

Principle #3Local quality

4Ease of operation

If foldable frame design is implemented, then installation ease is improved, but attachment security may be compromised

Engineering Contradiction:

Improveinstallation easeVSAvoidattachment security

Core Design Contradiction:

Ease of operationVSReliability

Solution Approach 1:

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

Inventive Principle:

Principle #3Local quality

Data Source

PatentEP3981071B1Methods and systems for folded frame solar panels

Publication Date: 2024.08.28 ORIGAMI SOLAR INC

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AI summary

Embodiments of the present invention may provide an elongated single piece of framework (59) which may be bent around a corner (46) perhaps for form an about 90 degree angle (61). An elongated single piece of framework (59) may have a first end (49) and a second end (50) which may be joined to each other or may be joined to other ends of a separate framework. A partial frame (48) or even a rectangular panel framework (3) may be created from at least one of an elongated single piece of framework which may frame a solar panel.