Solar Panel Frame Tab Connections for Low-Cost Assembly
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Solution Overview
Problem
The existing technologies for connecting frame components for solar panels are inefficient, requiring significant material and manufacturing costs, and complex assembly processes, which hinder the widespread adoption of renewable solar energy.
Innovation Solution
The development of a frame system that includes a first frame section with an elongated piece of framework material, featuring a lengthwise fold and a tab connection assembly, which allows for easy assembly and enhanced structural integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional connection methods are used for frame components, then structural strength may be adequate, but manufacturing costs and assembly complexity increase significantly
Solution Approach 1:
The frame is divided into multiple separate frame sections that can be manufactured independently using standard extrusion processes. Each frame section includes integrated connection features (tabs and holes) that enable assembly without requiring complex manufacturing processes for the entire frame structure, thereby reducing manufacturing costs while maintaining strength.
Solution Approach 2:
The connection features (tabs and holes) are integrated directly into the frame sections during the extrusion process, merging the structural frame elements with the connection elements. This eliminates the need for separate connection components and complex assembly operations, reducing both manufacturing cost and assembly complexity while maintaining structural integrity.
2Productivity
If traditional connection methods are used for frame components, then adequate connectivity may be achieved, but assembly process complexity and time increase
Solution Approach 1:
The frame system is segmented into modular frame sections with standardized connection features. This segmentation allows for pre-fabrication of individual sections and enables rapid assembly through simple alignment and connection of the modular units, significantly improving assembly speed while reducing process complexity.
Solution Approach 2:
The tab and hole connection features are designed to self-align and self-engage during assembly. The tabs automatically insert into the holes and lock into position, eliminating the need for complex alignment procedures or additional fastening operations. This self-service mechanism dramatically simplifies the assembly process and increases productivity.
3Reliability
If complex connection assemblies are used, then structural integrity may be maintained, but material costs and manufacturing complexity increase
Solution Approach 1:
The connection features are merged with the frame sections themselves rather than being separate components. The tabs and holes are formed as integral parts of the extruded frame sections, reducing the total number of parts and simplifying the connection assembly while maintaining structural durability through the robust extruded construction.
Data Source
AI summary
A frame for at least partially enclosing or supporting a panel is provided. The frame may include at least a first frame section that may include an elongated piece of framework material having a first end and a second end, wherein the first and second ends define a lengthwise dimension. The first frame section may further include lengthwise fold defining an intersection of a frame sidewall with a bottom flange, wherein the frame sidewall is characterized by a height extending from the bottom flange. The first frame section may further include a portion of at least one tab connection assembly where a connected element is attached to the first frame section. The tab connection assembly may include: i) at least one tab feature provided as part of either the first frame section or the connected element, and ii) at least one corresponding hole feature provided as part of the other of the first frame section or the connected element, wherein the hole feature may lockingly receives the at least one tab feature. The connected element may include another frame section, a cross bar, or a racking structure.