Methods and systems for reinforced mounting holes for solar panel frames
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Solution Overview
Problem
Existing solar panel frames lack sufficient strength, durability, and cost-effectiveness in their connection to racking systems, leading to challenges in installation and manufacturing efficiency.
Innovation Solution
The development of reinforced mounting holes and frame structures formed from a single piece of framework material, including a bottom flange, frame sidewall, and panel containment structures, with reinforced openings for improved attachment and high-strength modules.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional mounting holes are used in solar panel frames, then manufacturing is simpler, but attachment strength and durability to racking systems is insufficient
Solution Approach 1:
The frame is divided into functional zones: standard sections with conventional holes and reinforced sections with strengthened mounting holes. This segmentation allows the frame to achieve high attachment strength where needed while maintaining simplicity in other areas, resolving the contradiction between strength and complexity.
Solution Approach 2:
Reinforced mounting holes are implemented specifically at critical attachment points rather than throughout the entire frame. This local reinforcement provides enhanced attachment strength at key locations while minimizing the overall structural complexity and material usage.
2Reliability
If reinforced mounting holes with greater depth are provided, then attachment durability is improved, but manufacturing complexity increases
Solution Approach 1:
The reinforced mounting holes are formed during the initial frame manufacturing process using preliminary forming operations. By preparing the reinforced hole structures in advance during manufacturing rather than requiring post-assembly modifications, the patent achieves improved attachment durability while controlling manufacturing complexity.
Solution Approach 2:
The formation of reinforced mounting holes is merged with the existing frame manufacturing process. The reinforcing features are integrated into the hole-forming operation itself, combining multiple functions into a single manufacturing step, thereby improving durability without proportionally increasing manufacturing complexity.
3Ease of manufacture
If single-piece framework material is used, then manufacturing cost is reduced, but achieving reinforced mounting holes becomes more difficult
Solution Approach 1:
The reinforced mounting holes utilize the third dimension by creating depth variations and layered structures within the single-piece framework material. This dimensional approach allows reinforcement features to be formed within the material volume itself, achieving precise reinforcement while maintaining the cost benefits of single-piece construction.
Solution Approach 2:
The single-piece framework material incorporates composite structural features within its composition, combining different material densities or structural configurations in specific zones to create reinforced mounting holes. This allows precision reinforcement features to be achieved while maintaining the manufacturing simplicity of single-piece construction.
Data Source
AI summary
A frame (101) for supporting a solar panel (190) may include at least a first frame section (201-1), having a bottom flange (604) provided at a base of the first frame section (601) and a frame sidewall (603). A panel containment structure (191), at an upper portion of the frame sidewall, may have a lower shelf (105) extending from the sidewall (603). One or more reinforced mounting holes (822) may be provided in the bottom flange (804), in the frame sidewall (903), or both in the bottom flange and in the frame sidewall. The bottom flange, frame sidewall. (10) and panel containment structure may be formed at least in part from folds (102) provided in a single piece of first framework material, the first framework material having an average thickness. One or more reinforced mounting holes may include an opening having a depth greater than the framework thickness.