Hollow Panel Support Frame With Sealed Joints and Electrical Routing
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Solution Overview
Problem
Existing solar panel support frames face challenges with inadequate sealing at junctions, mechanical rigidity, corrosion, and labor-intensive installation, particularly when integrating photovoltaic panels on building surfaces.
Innovation Solution
A support frame with a peripheral structure comprising pre-cut, stamped, and welded metal strips, featuring wings for sealing and internal/external connection means, made from materials like austenitic stainless steel or iron-nickel alloys with controlled expansion, allowing for efficient electrical connections and aesthetic integration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If aluminum profiles are used for the frame uprights, then the frame can be assembled and fixed to the roof, but the frames become bulky and exhibit poor corrosion resistance
Solution Approach 1:
The patent changes the material parameter from aluminum to steel, fundamentally altering the properties of the frame uprights. This material substitution provides superior corrosion resistance and mechanical strength while enabling a different manufacturing approach (bending and welding steel strips instead of assembling aluminum profiles).
Solution Approach 2:
The frame uprights are constructed using composite material technology, specifically steel strips that may be coated or treated with corrosion-resistant layers. This combines the structural advantages of steel with protective surface treatments to achieve both strength and corrosion resistance.
2Strength
If aluminum frames are used, then the panels can be supported, but a lot of labor is required for installation and sealing
Solution Approach 1:
The steel strips are pre-cut, pre-bent, and pre-drilled with holes for connections before being shipped to the installation site. This preliminary preparation of components significantly reduces the labor required during actual installation, as workers only need to assemble the pre-prepared elements rather than performing complex bending and drilling operations on-site.
Solution Approach 2:
The frame is divided into modular uprights that can be independently manufactured and then assembled. This segmentation allows for standardized production of individual components that can be quickly assembled together, reducing installation complexity and labor requirements.
3Reliability
If joints are made in the junction zones of two adjacent panels, then sealing can be attempted, but the seals are difficult to make and do not always provide satisfactory sealing
Solution Approach 1:
The patent introduces an intermediary sealing element (such as a rubber or elastomeric seal) that is integrated into the frame structure at the junction zones. This intermediary material provides reliable sealing between adjacent panels while being easier to install than traditional sealing methods, as it is pre-positioned and requires minimal adjustment during assembly.
Solution Approach 2:
The sealing function is merged with the structural frame elements themselves. The uprights are designed to incorporate sealing channels or grooves that hold the sealing material, combining the structural support function with the sealing function in a single integrated component rather than using separate sealing systems.
4Strength
If aluminum frames are used, then panels can be supported, but the frames are not always suitable for making electrical junctions and may deteriorate aesthetic appearance
Solution Approach 1:
The steel frame uprights are designed to perform multiple functions simultaneously: structural support, corrosion resistance, and electrical connection. The uprights incorporate integrated electrical terminals or connection points that allow for easy electrical junctions between panels, making the same structural element versatile for both mechanical and electrical purposes.
Solution Approach 2:
The frame structure may incorporate composite material construction, combining steel for structural integrity with conductive materials or coatings that facilitate electrical connections. This allows the same component to provide both mechanical support and electrical conductivity without compromising either function.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution provides a lightweight, rigid, and corrosion-resistant frame that ensures effective sealing, reduces installation labor, and maintains the aesthetic appearance of solar panel installations while supporting electrical connections.
Implementation Method 1
The frame consists of at least one pre-cut metal strip, stamped, folded and assembled by welding, and in particular by laser welding
Implementation Method 2
an alloy with controlled expansion of the iron-nickel type or ferritic stainless steel
Data Source
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AI summary
The invention relates to a bearing frame for a panel, of the type comprising a peripheral structure (1, 1') for receiving a panel (20), including at least three mounts (2, 3, 4, 5, 2', 3', 4', 5') defining a frame in which the lower face defines a reference plane (P, P'), in which at least one mount (2, 5; 5') includes a wing (90,100; 90') extending on the entire length thereof towards the outside of the frame in parallel with the upper face of the frame, the frame comprising at least one precut metal strip (30) stamped, folded and assembled by welding, in particular laser welding, characterised in that the peripheral structure (1, 1') is hollow and in that it further comprises inner and outer connection means (14, 16, 17) and an electric linking means (18) between the inner and outer connection means, provided inside the hollow peripheral structure.