Interlocking Photovoltaic Module Frames for Dense Transport Stacking
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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 module frame with male and female alignment features that allow for secure interlocking and stacking of photovoltaic modules, eliminating the need for cardboard boxes and corner elements, enabling denser packing and reduced material costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If cardboard boxes and corner elements are used for packaging photovoltaic modules, then the modules are protected during transportation, but the shipping density is reduced and material costs increase
Solution Approach 1:
The patent removes the outer packaging (cardboard boxes) and corner protective elements from the transportation system. Instead, the photovoltaic modules themselves are designed with integrated protective features and interlocking capabilities, allowing them to protect and support each other without requiring separate packaging materials.
Solution Approach 2:
The protective and structural functions are merged into the module design itself. The frame structure includes integrated features that provide both protection and interlocking capability, eliminating the need for separate packaging components and reducing overall material usage while maintaining protection.
2Reliability
If cardboard boxes and corner elements are used for packaging photovoltaic modules, then the modules are protected during transportation, but material and labor costs increase
Solution Approach 1:
The patent eliminates the need for separate protective packaging materials (cardboard boxes, corner elements) by integrating protective functionality into the module's own structure. This reduces both material costs and the labor required for packaging and unpacking operations.
Solution Approach 2:
The modules are designed to protect themselves through their own structural features. The frame and interlocking mechanisms provide inherent protection during stacking and transportation, eliminating the need for external protective packaging and the associated labor for application and removal.
3Reliability
If conventional packaging with cardboard boxes is used, then modules are protected, but unpacking and recycling becomes labor-intensive
Solution Approach 1:
The patent removes the complex packaging system (cardboard boxes, corner elements, straps) that requires labor-intensive unpacking and recycling. The simplified system allows modules to be directly stacked and transported without outer packaging, eliminating the unpacking and recycling steps entirely.
Solution Approach 2:
By eliminating reusable packaging components like cardboard boxes and corner elements, the system avoids the entire unpacking and recycling process. The modules are designed to be handled directly in their transport configuration, making the packaging materials unnecessary and eliminating the associated labor burden.
4Device complexity
If photovoltaic modules are stacked without interlocking features, then transportation is simpler, but the stacking stability and shipping density are reduced
Solution Approach 1:
The patent divides the module frame into segments with specific interlocking features (protrusions and recesses) that enable stable stacking. These segmented features allow modules to connect to each other in a standardized way, providing stability while maintaining simplicity in the overall stacking process.
Solution Approach 2:
The interlocking features act as intermediaries between adjacent modules, providing the necessary connection and stability. These features facilitate stable stacking without requiring complex external fixtures or packaging, enabling direct module-to-module connection.
5Quantity of substance
If photovoltaic modules have interlocking alignment features, then stacking density and stability improve, but manufacturing complexity increases
Solution Approach 1:
The patent combines the interlocking features and alignment mechanisms directly into the frame structure during manufacturing. By integrating these features into the frame itself rather than adding them as separate components, the manufacturing process is simplified while still achieving the desired stacking density and stability.
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.