Solar module
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Solution Overview
Problem
Existing solar module frame profiles are costly due to limited design freedom in two spatial dimensions, making them inflexible and expensive to produce, especially for smaller quantities.
Innovation Solution
A one-piece metal strip frame profile with a U-shaped receiving section is constructed using rolling, punching, and bending processes, allowing for greater design flexibility and reduced production costs by forming the lower U-leg with spaced metal support sections and incorporating additional structural elements like screw-in rivets or metal brackets.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If extruded frame profiles are used, then manufacturing costs decrease for large quantities, but design freedom is limited to two spatial dimensions
Solution Approach 1:
The patent transitions from two-dimensional extrusion to three-dimensional rolling and bending processes. The frame profile is formed by rolling metal sheets and bending them into complex three-dimensional shapes, enabling design freedom in all spatial dimensions while maintaining cost-effectiveness for various production quantities
Solution Approach 2:
The frame profile is divided into multiple components including side edges, upper edges, lower edges, and corner connections that can be manufactured separately and assembled. This segmentation allows each component to be optimized independently using rolling and bending processes, achieving both design freedom and manufacturing efficiency
2Ease of manufacture
If rolled frame profiles are used, then production costs decrease for smaller quantities, but production complexity increases
Solution Approach 1:
Multiple manufacturing operations (rolling, punching, bending, cutting) are combined into a single integrated production line. The metal strip passes through sequential processing stations that perform multiple operations in one continuous flow, reducing overall production complexity despite the variety of operations required
Solution Approach 2:
Metal sheets are pre-cut and pre-punched with required patterns before entering the rolling and bending processes. This preliminary preparation simplifies the subsequent forming operations and enables faster production while maintaining design flexibility
3Stability of the object's composition
If continuous lower U-leg is used, then structural stability is improved, but manufacturing flexibility and cost-effectiveness decrease
Solution Approach 1:
The continuous lower U-leg is segmented into discrete sections that are separately formed and then joined together. This segmentation enables each section to be manufactured independently using cost-effective rolling and bending processes, while the joined sections provide sufficient structural stability for the solar module application
Solution Approach 2:
Joining elements such as rivets, screws, or adhesive layers are introduced as intermediaries to connect the segmented lower U-leg sections. These intermediaries maintain the structural integrity and stability of the frame while allowing the sections to be manufactured separately, achieving both stability and manufacturing flexibility
Data Source
Figure 1a~1b
Figure 2~4
Figure 5~6
AI summary
The invention relates to a solar module having a solar module laminate (1), which has, as solar module laminate edges, two lateral edges, an upper edge and a lower edge, wherein a frame profile (2) extended along a direction of extension (E) is secured on at least one of the lateral edges and/or on the upper edge and/or on the lower edge of the solar module laminate (1), which frame profile has in the cross-section an outer edge (20) and a U-shaped receiving section (21) with an upper U-shaped limb (22) and a lower U-shaped limb (23) for receiving one of the solar module laminate edges. According to the present invention, the frame profile (2) is integrally constructed from a metal strip, which forms the outer edge (20) of the frame profile with an edge plane, wherein the upper U-shaped limb (22) is configured as an upturn of the entire metal strip from the edge plane, and the lower U-shaped limb (23) is configured as metal support sections (22a, 22b, 22c) adjacent in the direction of extension (E) and spaced apart from one another, which metal support sections are bent away from the edge plane of the metal strip as integral parts of the metal strip.