Single-walled connecting key framesets
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Solution Overview
Problem
Existing photovoltaic (PV) module assembly methods lack efficient and cost-effective solutions for securely connecting single-wall and double-wall frame sections while maintaining electrical continuity, leading to increased material costs and complex assembly processes.
Innovation Solution
The use of connecting keys made from various materials such as metals, polymers, and ceramics, which can be secured to frame sections using screws, rivets, welding, or frictional fits, and serve as both corner and central hubs to connect multiple frame sections, ensuring electrical continuity through conducting strips and clips.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If double-wall frame sections are used to ensure structural strength and electrical continuity, then reliability is improved, but material costs and device complexity increase
Solution Approach 1:
The frame is divided into modular single-wall and double-wall sections that can be independently manufactured and assembled. Connecting keys serve as discrete components that join these sections, allowing the system to achieve the required structural strength and electrical continuity only where needed rather than throughout the entire frame structure.
Solution Approach 2:
Connecting keys act as intermediary components between single-wall and double-wall frame sections. These keys provide both mechanical connection for structural integrity and electrical connection for continuity, eliminating the need for complex integrated designs while maintaining both reliability functions.
2Strength
If traditional connection methods are used to secure frame sections, then structural strength is improved, but assembly time and productivity are reduced
Solution Approach 1:
The connecting keys are pre-configured with both mechanical fastening features (screw holes, rivet holes, or friction-fit geometries) and electrical contact surfaces before assembly. This preliminary preparation allows workers to simply insert and secure the keys without performing multiple separate operations, thereby maintaining strong connections while significantly improving assembly speed.
Solution Approach 2:
The connecting key merges multiple functions into a single component: structural connection, electrical continuity, and alignment. By combining what would traditionally require separate operations (mechanical fastening and electrical bonding) into one integrated component, the assembly process is simplified and accelerated while maintaining connection strength.
3Loss of substance
If single-wall frame sections are used to reduce material costs, then material usage is reduced, but structural strength and electrical continuity may be compromised
Solution Approach 1:
The frame structure uses single-wall sections (lower material usage) in areas where high strength and conductivity are not critical, while strategically placing double-wall sections (higher material usage) at locations requiring enhanced structural or electrical performance. The connecting keys enable this non-uniform distribution by providing reliable connections between different wall types.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach reduces material costs by allowing for the use of single-wall framesets with reduced material usage while maintaining electrical continuity and simplifying the assembly process through versatile connection methods, including friction fits and adhesives, thereby enhancing the efficiency and reliability of PV module assembly.
Implementation Method 1
frictional fits
Implementation Method 2
ensuring electrical continuity through conducting strips and clips
Data Source
AI summary
Frames and processes of manufacture using single-wall frame sections coupled to other single-wall frame sections or double-wall frame sections using a connecting key are provided. The connecting key can be metallic, polymer, ceramic, a laminate, and combinations thereof.