Polyamide Solar Panel Frame for Lightweight Electrical Insulation
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Solution Overview
Problem
Existing solar panel structural supports face challenges in being lightweight, electrically non-conductive, thermally resistant, and mechanically stable while withstanding various environmental conditions, and they often require complex manufacturing processes and do not meet stringent UL laboratory standards for flame retardancy and electrical insulation.
Innovation Solution
A framing structure for solar panels made from a polymer composition comprising polyamide polymers and reinforcing fillers, which can be easily manufactured using injection molding, providing flexibility, stiffness, and excellent electrical insulation and flame retardancy, allowing for complex shapes and integrated components like junction boxes and cable routing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If aluminum frames are used for solar panels, then mechanical strength and structural stability are improved, but weight increases and electrical conductivity causes current loss
Solution Approach 1:
The patent employs composite materials consisting of polyamide polymer matrix combined with reinforcing fillers (glass fibers, mineral fillers, or natural fibers) to create a framing structure that achieves aluminum-like mechanical strength while maintaining lightweight properties and electrical non-conductivity. The composite structure provides both structural integrity and the desired electrical insulation properties.
2Strength
If aluminum frames are used for solar panels, then structural support is provided, but electrical conductivity leads to current loss affecting efficiency
Solution Approach 1:
The polyamide-based composite framing structure provides the necessary structural support while being inherently electrically non-conductive, thereby eliminating current loss through the frame. The composite material combines structural reinforcement with electrical insulation properties that prevent energy loss.
3Weight of moving object
If polyester or polyepoxide supports are used, then lightweight properties are achieved, but thermal resistance deteriorates at extreme temperatures
Solution Approach 1:
The patent uses polyamide polymers combined with reinforcing fillers to create a composite that maintains thermal stability at extreme temperatures (from -40°C to +85°C and beyond) while retaining lightweight properties. The polyamide matrix provides superior thermal resistance compared to polyester or polyepoxide, and the filler reinforcement enhances both mechanical strength and thermal stability.
4Reliability
If complex manufacturing processes are used for polyurethane frames, then flame retardancy and mechanical properties are improved, but manufacturing time and complexity increase
Solution Approach 1:
The patent employs a polyamide-based composite that inherently provides flame retardancy and mechanical strength through its composition and reinforcement structure, eliminating the need for complex multi-step manufacturing processes. The composite material achieves UL 94 V-0 flame rating and meets IEC 61215 standards through its material properties rather than complex processing.
5Strength
If aluminum frames undergo significant machining and welding, then structural integrity is maintained, but manufacturing costs and time increase
Solution Approach 1:
The patent transitions from metal processing parameters (machining, welding) to polymer composite processing parameters (molding, casting), enabling direct formation of complex frame structures without sequential manufacturing steps. This parameter change in the manufacturing approach significantly improves productivity while maintaining structural integrity through the composite material properties and molding process.
Data Source
AI summary
The invention pertains to a framing structure for a solar panel made from a polymer composition (C) comprising at least one polyamide polymer [polyamide (A)], and at least one reinforcing filler [filler (F)], the framing structure being characterized by having a top surface and a bottom surface, said top surface having a depressed central portion sized for receiving a solar panel. It also relates to a method for manufacturing the same, to a method for assembly a solar panel into said framing structure, to a solar panel assembly comprising the same, and to a method for fixing said solar panel assembly onto a support (e.g. a roof).