Interlocking Photovoltaic Module Frames for Dense 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

The use of frames with male and female alignment features on photovoltaic modules allows for direct interlocking and stacking during transportation, eliminating the need for cardboard boxes and corner elements, enabling denser packing and reducing material and labor costs.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If conventional packaging solutions (cardboard boxes and corner elements) are used for photovoltaic modules, then modules are protected during transportation, but shipping density is reduced and material costs increase

Engineering Contradiction:

Improvemodule protection during transportationVSAvoidshipping density

Core Design Contradiction:

ReliabilityVSVolume of stationary object

Solution Approach 1:

The invention extracts and eliminates the cardboard boxes and corner elements from the packaging system. Instead of using these separate packaging components, the photovoltaic modules are designed with integrated interlocking features that allow them to support each other directly, removing the need for additional packaging materials and achieving dense stacking configuration.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The invention merges the protective function previously provided by separate packaging materials (cardboard boxes and corner elements) into the module structure itself. The interlocking features integrate the functions of protection, alignment, and stacking support into the module frame, eliminating the need for separate packaging components.

Inventive Principle:

Principle #5Merging (Combining)

2Reliability

If conventional packaging solutions (cardboard boxes and corner elements) are used for photovoltaic modules, then modules are protected during transportation, but material costs increase

Engineering Contradiction:

Improvemodule protection during transportationVSAvoidmaterial costs

Core Design Contradiction:

ReliabilityVSLoss of substance

Solution Approach 1:

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The invention replaces expensive packaging materials (cardboard boxes and corner elements) with the module's own structural features. The interlocking mechanism uses the module frame itself as the protective element, eliminating the need for disposable packaging materials and reducing overall material costs.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

3Reliability

If conventional packaging solutions (cardboard boxes and corner elements) are used for photovoltaic modules, then modules are protected during transportation, but labor requirements for unpacking and recycling increase

Engineering Contradiction:

Improvemodule protection during transportationVSAvoidunpacking and recycling labor

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The invention enables the modules to protect themselves during transportation through their own interlocking features, without requiring external packaging materials. The modules self-assemble into a stable configuration during stacking, eliminating the need for manual unpacking and recycling of packaging materials.

Inventive Principle:

Principle #25Self-service

4Volume of stationary object

If frames with alignment features are used for direct interlocking, then shipping density increases and material costs decrease, but module complexity increases

Engineering Contradiction:

Improveshipping densityVSAvoidframe structure complexity

Core Design Contradiction:

Volume of stationary objectVSDevice complexity

Solution Approach 1:

The invention makes the frame structure multi-functional by integrating alignment features, interlocking mechanisms, and protective functions into a single component system. The alignment features on the top and bottom members serve both as structural elements and as guides for proper stacking orientation, eliminating the need for separate packaging components.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The invention segments the frame into distinct top and bottom members with complementary alignment features. This segmentation allows for standardized manufacturing of individual components that can be easily assembled into various stacking configurations, reducing overall system complexity while maintaining high shipping density.

Inventive Principle:

Principle #1Segmentation

Data Source

PatentUS8258395B2Photovoltaic module and interlocked stack of photovoltaic modules

Publication Date: 2012.09.04 MAXEON SOLAR PTE LTD

AI summary

One embodiment relates to an arrangement of photovoltaic modules configured for transportation. The arrangement includes a plurality of photovoltaic modules, each photovoltaic module including a frame having at least a top member and a bottom member. A plurality of alignment features are included on the top member of each frame, and a plurality of alignment features are included on the bottom member 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.