Single-Piece Extruded Solar Panel Frame for Simplified Manufacturing
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Solution Overview
Problem
Existing solar panel frames are large, heavy, and costly, requiring improved strength, manufacturing efficiency, and reduced installation time while maintaining durability and cost-effectiveness.
Innovation Solution
Frames are constructed from a single piece of framework material with features like bottom flanges, sidewalls, and panel containment structures, utilizing materials like coated steel for enhanced strength and ease of assembly, and incorporating cross bars for additional support.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional multi-component frame structures are used, then manufacturing flexibility is maintained, but manufacturing complexity and cost increase
Solution Approach 1:
The patent combines multiple frame components (side rails, cross members, mounting brackets) into a single monolithic extruded profile. This integration eliminates the need for separate manufacturing and assembly steps for individual components, directly reducing manufacturing complexity while maintaining structural functionality.
Solution Approach 2:
The single extruded frame profile performs multiple functions simultaneously: it provides structural support, includes integrated mounting features for solar panels, incorporates reinforcement elements, and offers attachment points for cables. This multi-functionality consolidates what would traditionally require multiple specialized components into one universal structure.
2Productivity
If single-piece extruded frames are used, then manufacturing efficiency improves, but frame weight increases
Solution Approach 1:
The extruded frame profile incorporates localized reinforcement elements (such as internal ribs, thickened sections, or embedded strengthening features) only where structural support is needed, rather than uniformly increasing the thickness of the entire frame. This allows the frame to achieve required strength with minimal additional material, controlling overall weight while maintaining manufacturing efficiency.
3Strength
If reinforced frame structures are added, then panel support strength improves, but manufacturing complexity increases
Solution Approach 1:
Reinforcement elements are integrated directly into the extruded profile design rather than being added as separate components. The strengthening features (internal ribs, thickened walls, or embedded elements) are formed as part of the single extrusion process, eliminating the need for additional assembly steps while providing enhanced panel support strength.
Data Source
AI summary
A frame 101 for at least partially enclosing or supporting a panel 190 is provided. The frame may include at least a first frame section 201-1 including a bottom flange 104 provided at a base of the frame section. A frame sidewall 103 may be provided at an outer portion of the frame section, the frame sidewall characterized by a height H extending from the bottom flange 104. A panel containment structure 101-1 may be provided at an upper portion of the frame sidewall 103, the panel containment structure including a lower shelf 105 extending from the frame sidewall. A support wall 431-1 may be provided at an inner portion of the frame section 201-1, the support wall extending (i) between the bottom flange 104 and the frame sidewall 103, (ii) between the bottom flange 104 and the lower shelf 105, or (iii) both (i) and (ii).