Interlocked Photovoltaic Module Frame for Packaging-Free Shipping
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Solution Overview
Problem
Conventional packaging solutions for photovoltaic modules are inefficient, leading to high costs, labor-intensive unpacking and recycling, and reduced shipping density due to the use of cardboard boxes and corner elements, which result in wasted space and increased material costs.
Innovation Solution
A modular frame with male and female alignment features allows for direct interlocking and stacking of photovoltaic modules, eliminating the need for cardboard boxes and corner elements, enabling denser packing and reduced material costs by using a frame that maintains module integrity during transportation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If cardboard boxes and corner elements are used for packaging photovoltaic modules, then module protection during transportation is achieved, but shipping density is reduced and material costs increase
Solution Approach 1:
The patent integrates the packaging function directly into the module frame structure by incorporating corner elements and alignment features as built-in components. This merging eliminates the need for separate external packaging materials like cardboard boxes, thereby maintaining module protection while maximizing shipping density by removing unnecessary packaging volume.
Solution Approach 2:
The patent extracts the packaging function from external materials (cardboard boxes) and embeds it within the module frame itself through integrated corner elements and alignment features. This extraction of the packaging function into the structural components allows modules to be stacked and protected without requiring additional external packaging volume.
2Reliability
If cardboard boxes and corner elements are used for packaging photovoltaic modules, then module protection during transportation is achieved, but material and labor costs increase
Solution Approach 1:
The patent combines the protective corner elements and alignment features as integrated parts of the module frame structure. This merging eliminates the need for separate packaging materials and the labor associated with their application and removal, thereby reducing both material costs and labor costs while maintaining module protection during transportation and installation.
Solution Approach 2:
The module frame's integrated corner elements and alignment features provide self-protection and self-alignment capabilities. The structure serves its own packaging and installation needs without requiring external packaging materials or additional labor for packaging operations, thereby reducing material and labor costs while ensuring module protection.
3Reliability
If conventional packaging with cardboard boxes is used, then module protection is provided, but unpacking and recycling processes become labor-intensive
Solution Approach 1:
The patent extracts the packaging function from removable external materials (cardboard boxes) and embeds it permanently into the module frame structure through integrated corner elements. This extraction eliminates the unpacking process entirely, as the protective features are built-in and require no removal or recycling, thereby dramatically improving productivity by eliminating labor-intensive unpacking and recycling operations.
Solution Approach 2:
The integrated corner elements and alignment features provide continuous protective and alignment functions without requiring external packaging materials. The structure serves its own packaging needs permanently, eliminating the need for unpacking and recycling operations that would otherwise require labor, thereby improving productivity.
4Reliability
If separate packaging materials are used, then module protection is achieved, but device complexity increases
Solution Approach 1:
The patent merges the protective corner elements and alignment features into the module frame structure as integrated components. This merging reduces device complexity by eliminating separate packaging materials and their associated assembly and disassembly operations, while maintaining module protection through the built-in structural features.
Data Source
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AI summary
One embodiment relates to an arrangement (900) of photovoltaic modules configured for transportation. The arrangement includes a plurality of photovoltaic modules (902), each photovoltaic module including a frame (602) having at least a top member (608) and a bottom member (604). A plurality of alignment features (506) are included on the top member (608) of each frame, and a plurality of alignment features (610) are included on the bottom member (604) of each frame. Adjacent photovoltaic modules are interlocked by the alignment features on the top member of a lower module fitting together with the alignment features on the bottom member of an upper module. Other embodiments, features and aspects are also disclosed.