Folded Single-Piece Frame for Solar Panels to Lower Manufacturing Cost

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Solution Overview

Problem

The cost of photovoltaic solar panel frames has remained high due to unchanged materials and manufacturing processes, while solar panel efficiency and installation costs have decreased, necessitating a reduction in frame costs and installation complexity.

Innovation Solution

A foldable frame design for solar panels made from materials like aluminum or steel, which can be bent to form a 90-degree angle, reducing material usage and manufacturing costs, and featuring attachments and sealants for secure assembly and attachment 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, fixed structure to a flexible, formable structure that can be bent and shaped during installation to match panel contours, reducing the need for precise pre-manufacturing and multiple components

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The frame material properties are changed to allow flexibility and formability, enabling the frame to be shaped on-site and reducing manufacturing complexity while maintaining structural integrity

Inventive Principle:

Principle #35Parameter changes

2Reliability

If traditional multi-component frame assemblies are used, then structural integrity is achieved, but installation complexity increases

Engineering Contradiction:

Improvestructural integrityVSAvoidassembly complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

Multiple separate frame components (side frames, end frames, corners) are merged into a single continuous flexible frame that can be formed into the complete rectangular structure, eliminating the need for assembly of multiple parts

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The flexible frame serves multiple functions: it provides structural support, conforms to panel contours, and simplifies installation all through a single component design

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Manufacturing precision

If precise pre-fabricated frames are used, then fit accuracy is improved, but manufacturing cost increases

Engineering Contradiction:

Improvefit accuracyVSAvoidmanufacturing cost

Core Design Contradiction:

Manufacturing precisionVSEase of manufacture

Solution Approach 1:

The frame is prepared in a flexible state before installation, allowing it to be formed to the exact contours of the panel on-site, achieving precise fit without complex pre-manufacturing processes

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

Instead of making the frame rigid and precisely fitting it during manufacturing, the approach is inverted by making the frame flexible and achieving precise fit during installation through forming

Inventive Principle:

Principle #13The other way round (Inversion)

Data Source

PatentUS20240266994A1Methods and Systems for Folded Frame Solar Panels

Publication Date: 2024.08.08 NEXTPOWER LLC

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.