Solar module and solar module frame

Solution Overview

Problem

Current solar module frames are complex and costly due to multiple parts, such as face covering elements and corner connectors, leading to high material costs and increased weight, making production and installation inefficient.

Innovation Solution

A solar module frame assembled by connected frame profiles with corner connections formed by a flap, eliminating the need for corner connectors and allowing for optimized profile cross-sections and material usage, such as using steel instead of aluminum, to reduce costs and enhance module stiffness.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If traditional corner connectors and face covering elements are used to assemble the solar module frame, then the frame achieves sufficient structural stability, but material costs increase and production complexity increases

Engineering Contradiction:

Improvestructural stabilityVSAvoidproduction complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent integrates the corner connection function directly into the frame profiles themselves through integrated connection elements (such as flaps or bending sections) that are formed as part of the profile during extrusion. This merging eliminates separate corner connectors and face covering elements, reducing the number of components from multiple separate parts to a unified frame structure assembled with fewer elements.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The frame profiles are designed with multi-functional integrated connection elements that simultaneously serve as structural support members and corner connection mechanisms. The same profile provides both the framing function and the corner joining function through features like flaps that can be bent or folded to create rigid corner joints, eliminating the need for specialized corner connectors.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Reliability

If traditional corner connectors and face covering elements are used to assemble the solar module frame, then the frame achieves sufficient structural stability, but material costs and weight increase

Engineering Contradiction:

Improvestructural stabilityVSAvoidframe weight

Core Design Contradiction:

ReliabilityVSWeight of moving object

Solution Approach 1:

The patent integrates the corner connection function directly into the frame profiles themselves through integrated connection elements (such as flaps or bending sections) that are formed as part of the profile during extrusion. This merging eliminates separate corner connectors and face covering elements, reducing the number of components from multiple separate parts to a unified frame structure assembled with fewer elements.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent extracts and eliminates unnecessary components (corner connectors, face covering elements) from the frame assembly, retaining only the essential frame profiles with integrated connection capabilities. This extraction reduces material usage and overall frame weight while maintaining structural integrity through the optimized profile design.

Inventive Principle:

Principle #2Taking out (Extraction)

3Reliability

If traditional corner connectors and face covering elements are used to assemble the solar module frame, then the frame achieves sufficient structural stability, but production time and installation effort increase

Engineering Contradiction:

Improvestructural stabilityVSAvoidproduction efficiency

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The patent integrates the corner connection function directly into the frame profiles themselves through integrated connection elements (such as flaps or bending sections) that are formed as part of the profile during extrusion. This merging eliminates separate corner connectors and face covering elements, reducing the number of components from multiple separate parts to a unified frame structure assembled with fewer elements.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The integrated connection elements (flaps, bending sections) are pre-formed as part of the frame profile during the extrusion process, so no additional assembly steps are required during frame construction. The profiles arrive at the assembly stage already prepared with their corner connection features, enabling rapid assembly without separate attachment operations.

Inventive Principle:

Principle #10Preliminary action

Data Source

PatentUS10651783B2Solar module and solar module frame

Publication Date: 2020.05.12 HANWHA Q CELLS GMBH

AI summary

A solar module having a solar module laminate and a rectangular solar module frame which supports the solar module laminate and is assembled by frame profiles which are respectively connected to each other by pairs to a corner connection, wherein at least one of the corner connections is formed by connection of a first frame profile of the frame profiles to an adjacent second frame profile of the frame profiles by a flap. Further, the invention relates to a solar module frame designed to support a solar module laminate and assembled by frame profiles which are respectively connected to each other by pairs to a corner connection, wherein at least one of the corner connections is formed by connection of a first frame profile of the frame profiles to an adjacent second frame profile of the frame profiles by means of a flap.