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 and structural integrity, 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 and reducing material costs by allowing for mixed material configurations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional connection methods are used for PV frame sections, then structural integrity can be maintained, but material costs increase and assembly processes become complex
Solution Approach 1:
The connection system is segmented into separate functional components: connecting keys for mechanical attachment and separate conductive elements for electrical continuity. This allows each component to be optimized independently, simplifying manufacturing while ensuring both structural and electrical requirements are met through modular assembly.
Solution Approach 2:
Connecting keys serve as intermediary elements between frame sections, providing a standardized interface that simplifies assembly. These keys can be made from various materials including conductive polymers that simultaneously provide mechanical connection and electrical continuity, reducing the need for multiple separate components.
2Quantity of substance
If mixed material configurations are used for frame sections, then material costs are reduced, but maintaining electrical continuity becomes difficult
Solution Approach 1:
The frame structure uses local quality by allowing different materials in different sections (single-wall vs double-wall, different metals or polymers) while incorporating localized conductive features at connection points. Connecting keys can be made from conductive materials or include conductive elements specifically at the interfaces where electrical continuity is required, while other portions of the frame can use cost-effective non-conductive materials.
Solution Approach 2:
The patent employs composite materials, particularly conductive polymers that combine the mechanical properties of polymers with electrical conductivity. These composite materials enable mixed-material frame configurations while maintaining electrical continuity through the connecting keys and conductive elements, allowing cost optimization without sacrificing electrical performance.
3Quantity of substance
If single-wall frame sections are used, then material costs are reduced, but connection strength and structural integrity are compromised
Solution Approach 1:
The connection system incorporates dynamic elements such as friction-fit mechanisms and interlocking geometries that adapt to manufacturing tolerances and assembly variations. Connecting keys for single-wall sections are designed with features that maximize contact area and mechanical interlocking, providing sufficient connection strength while maintaining the cost advantages of single-wall construction.
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.