Hollow-Fin Solar Mirror Frame Node for Low-Deflection Support
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Solution Overview
Problem
Existing solar mirror frame designs face challenges in reducing frame weight while maintaining rigidity and efficiency, particularly in managing torque and deflections to optimize solar energy collection and reduce costs.
Innovation Solution
The introduction of a hollow fin node design with a radially extending fin where at least 5% of the volume is replaced by a void, allowing for improved load distribution and reduced deflections, along with a torque plate system for efficient torque transmission, enhances the structural integrity and weight reduction of the solar mirror frame.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of stationary object
If frame weight is reduced to lower costs, then manufacturing cost decreases, but frame rigidity and load carrying capacity deteriorate
Solution Approach 1:
The patent applies hollow fin nodes with internal voids (at least 5% of fin volume is hollow) instead of solid material. This creates a porous-like structure that reduces weight while maintaining structural integrity through the strategic placement of voids in non-critical areas of the fin geometry.
Solution Approach 2:
The patent combines different geometric configurations (hollow fins, solid nodes, varying fin thicknesses) within a single frame structure. This composite approach allows optimization of each component for its specific loading conditions, achieving overall weight reduction without compromising frame rigidity.
2Weight of stationary object
If hollow fin node design is used to reduce weight, then part weight decreases, but manufacturing complexity increases
Solution Approach 1:
The node is divided into distinct functional components: a solid central node body and separate radial fins with hollow sections. This segmentation allows each component to be manufactured and analyzed independently, simplifying the overall manufacturing process despite the complex final geometry.
Solution Approach 2:
The hollow voids are strategically positioned only in specific regions of the fins where material removal does not compromise structural integrity. This local application of material reduction maintains manufacturing feasibility while achieving weight savings in non-critical areas.
3Weight of stationary object
If material is removed from fins to reduce weight, then weight decreases, but stress distribution and structural integrity may worsen
Solution Approach 1:
The hollow fin design creates a controlled porous structure where voids are positioned to avoid high-stress regions. The remaining material is strategically distributed to maintain adequate stress carrying capacity while reducing overall weight.
Solution Approach 2:
The patent varies fin parameters (thickness, length, hollow section dimensions) along the fin geometry to optimize the balance between weight reduction and stress distribution. Critical regions maintain higher material density while non-critical regions have reduced material content.
Data Source
AI summary
A method for producing a node for solar mirror frame having the steps of placing an aluminum billet having a diameter of less than 13 inches into a die. There is the step of extruding the billet through the die so an extrusion is formed having an elongate portion to which a structural element is attached, and a fin extending radially outward from the elongate portion where at least 5% of the volume of the fin is replaced by at least a single void extending essentially in parallel with the elongate portion, the elongate portion and the fin having a circle diameter of less than 12 inches; and cutting the extrusion to form the node.