Interlocking frame for solar panels
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Solution Overview
Problem
The high cost and complexity of manufacturing and installing frames for large and heavy solar panels hinder the widespread adoption of renewable solar energy solutions.
Innovation Solution
A frame precursor structure is designed with bendable sidewalls and interlocking features, allowing for the formation of a frame from a single piece of framework material, which reduces material costs and simplifies assembly by using notches and locking elements to secure the frame sections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional multi-piece frame structures are used for solar panels, then frame strength and durability are improved, but manufacturing complexity and installation costs increase
Solution Approach 1:
The patent merges multiple frame pieces into a single-piece frame structure that encloses the solar panel. The frame is formed from one continuous piece of material with integrated corners and sides, eliminating the need for separate corner pieces and fasteners. This reduces manufacturing complexity while maintaining structural integrity through the unified design.
Solution Approach 2:
The single-piece frame is designed with integrated segmentation features where each side and corner is formed as part of the continuous material. The corners are bent and folded into place to create distinct functional segments (sides and corners) while remaining part of the same piece, providing both structural division and manufacturing simplicity.
2Strength
If traditional multi-piece frame structures with separate fasteners are used, then assembly strength is improved, but installation time and labor costs increase
Solution Approach 1:
The frame combines the functions of multiple components (corner pieces, side pieces, and fasteners) into a single integrated structure. The corners are formed as bent sections of the same piece of material that forms the sides, eliminating the need for separate fasteners and reducing assembly steps to simply attaching the frame to the panel.
Solution Approach 2:
The frame structure is self-assembling through its bent and folded geometry. The corners are designed to fold into place and interlock with the sides without requiring external fasteners or complex assembly tools. The structure serves its own assembly function through its inherent geometric design, reducing installation time and labor requirements.
3Reliability
If multiple separate frame components and fasteners are used, then structural durability is improved, but material costs and manufacturing complexity increase
Solution Approach 1:
The patent combines multiple frame components (corners and sides) into a single continuous piece of material. This unified structure eliminates the need for separate corner pieces and fasteners, reducing the number of parts from four or more to one. The integrated design maintains structural durability through the continuous material while simplifying the overall frame structure.
Solution Approach 2:
The single-piece frame incorporates functional segmentation through bent and folded sections that create distinct sides and corners. Each segment is formed from the continuous material through bending and folding, providing structural differentiation without requiring separate components. This segmentation maintains durability while reducing complexity.
Data Source
AI summary
A frame precursor structure (201) is provided for use in forming a frame (101) that encloses at least a portion of a panel (190). The frame precursor structure may include a framework material having a first end (210) and a second end (220), the first and second ends defining a lengthwise dimension. A lengthwise fold (102) may define an intersection of a frame sidewall (103) with a bottom flange (104). A first corner bend precursor axis (212) on the frame sidewall may define the interface of a first frame section (201-1) with a second frame section (201-2). The sidewall at the first corner bend precursor axis (212) may be bendable along its height axis. The bottom flange may include a first notch (212N) at the first corner bend precursor axis (212).