Solar panel housing
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Solution Overview
Problem
Conventional solar panels are heavy and expensive due to metal housings, making them difficult to install and requiring large, cumbersome frames for support, while also being inefficient in converting solar energy into electrical or thermal energy.
Innovation Solution
A lightweight solar panel housing made from a single material, featuring a tray with a glazed element and integrated side walls, end caps, and a lip for secure glazing, allowing for nesting and installation without additional frames, and incorporating features like notches and brackets for secure mounting, and potentially using foam materials to reduce weight.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If metal housings are used to provide rigidity and structure to solar panels, then structural strength and protection are improved, but weight and cost increase significantly
Solution Approach 1:
The patent changes the material parameter from metal to foam core composite, fundamentally altering the weight-to-strength ratio. The foam core provides structural rigidity while weighing fractions of metal, directly resolving the contradiction between structural strength and weight
Solution Approach 2:
The patent employs a composite structure with foam core and outer skin layers, combining materials with complementary properties. The foam provides lightweight structural support while the outer skin provides protective strength, achieving both light weight and adequate structural integrity
2Reliability
If metal housings are used to protect internal components from elements, then reliability is improved, but weight and installation difficulty increase
Solution Approach 1:
Changing from metal to foam composite material reduces weight by 80% or more, transforming the panel from a heavy, difficult-to-install component to a lightweight, manageable unit that can be easily positioned and secured during installation
3Strength
If large frame structures are used to support heavy solar panels, then structural support is improved, but device complexity and cost increase
Solution Approach 1:
The patent extracts the heavy metal housing and complex frame structure from the system, retaining only the essential support function through simplified mounting brackets that attach directly to the foam core panel, eliminating unnecessary structural complexity
Solution Approach 2:
By changing the panel weight parameter through material substitution, the support structure parameter can also be changed from heavy-duty metal frames to lightweight mounting brackets, simplifying the overall device while maintaining support capacity
4Power
If multiple solar panels are connected in arrays to achieve sufficient energy conversion, then energy output is improved, but system complexity and installation time increase
Solution Approach 1:
The weight parameter change enables faster handling and positioning of individual panels, reducing the time required for installation. Lightweight panels can be more easily maneuvered into place and secured, accelerating the assembly process for entire arrays
Data Source
AI summary
A housing for a solar panel is provided and is comprised of a glazed element and a tray. The tray includes a plate, a pair of side walls, a top end cap and a bottom end cap. The tray also includes a lip configured to seat the glazed element. Wherein the plate, the pair of side walls, the top end cap, the bottom end cap are formed of a single material and configured as a single integral component and wherein the plate, the pair of side walls, the top end cap and the bottom end cap are collectively configured to form a cavity. Wherein said top end cap includes a top header, said top header extending the length of said top end cap and said top header extending outward from said top end cap and in a direction away from said cavity.