Folded Solar Panel Frame Structure for Lower-Cost Assembly
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The cost of photovoltaic solar panel frames has remained high due to unchanged materials and manufacturing processes, while installation costs for these frames have decreased mainly due to racking improvements, necessitating a reduction in frame costs, manufacturing costs, and installation costs.
Innovation Solution
The development of a foldable frame system for solar panels that can be bent to form 90-degree angles, allowing for a single-piece frame to encase a laminate, providing increased strength and rigidity, and featuring attachments and securements for easy installation, such as corner brackets and flexible angular protrusions for secure attachment to racking systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional rigid frames are used for solar panels, then structural strength is maintained, but material costs and manufacturing costs remain high
Solution Approach 1:
The frame transitions from a rigid structure to a flexible structure that can be bent into shape. The flexible frame material allows the frame to be bent around the solar panel at corners to form 90-degree angles, eliminating the need for complex assembly of multiple rigid pieces while maintaining structural strength through proper bending and securing mechanisms.
Solution Approach 2:
The frame material properties are changed to allow flexibility and bendability. By changing the material parameters to enable bending without breaking, the frame can be formed into the required shape more easily and at lower cost, while still providing the necessary structural support when properly installed.
2Stability of the object's composition
If traditional multi-piece frames are used, then structural stability is achieved, but installation complexity increases
Solution Approach 1:
Multiple separate frame pieces are merged into a single flexible frame that can be bent into the required shape. This single flexible frame replaces what would traditionally require multiple separate pieces joined together, simplifying the overall structure and reducing assembly complexity while maintaining the same structural stability when installed.
Solution Approach 2:
The frame incorporates dynamic flexibility during installation, allowing it to be bent and shaped to fit the panel. Once installed, the frame provides static stability through proper securing mechanisms. This dynamic-to-static transition enables both ease of installation and structural stability.
3Strength
If rigid frames with multiple components are used, then structural integrity is maintained, but installation time increases
Solution Approach 1:
The frame is pre-formed or can be easily bent into its final shape before installation. This preliminary shaping action eliminates the need for complex on-site assembly and adjustments during installation, significantly reducing installation time while maintaining structural integrity through proper bending and securing.
Solution Approach 2:
Multiple frame components are combined into a single flexible frame that maintains structural integrity when properly installed. This consolidation reduces the number of assembly steps and fastening operations required during installation, thereby reducing installation time while preserving the structural strength needed for proper support.
Data Source
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.