Solar Panel Corner Piece for Mixed-Width Frame Palletization

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Solution Overview

Problem

Conventional corner pieces for solar cell panel palletization fail to effectively interlock frames with different widths, leading to increased production costs and handling inefficiencies, as they require separate corner pieces for each width type and can cause damage during stacking and transportation.

Innovation Solution

A corner piece design featuring a right-angled corner part with a support piece, pressing piece, and locking protrusions that accommodate frames with different widths, allowing for secure interlocking and stable stacking without the need for multiple corner piece types, using a combination of first and second locking protrusions and a tension piece for flexible adaptation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If conventional corner pieces with single locking protrusion are used, then frames with same width can be tightly fixed, but frames with different widths cannot be properly locked

Engineering Contradiction:

Improvecompatibility with different frame widthsVSAvoidnumber of corner piece types

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The corner piece is designed with both a first locking protrusion and a second locking protrusion, enabling a single corner piece to accommodate frames of different widths. The first locking protrusion engages with wider frames while the second locking protrusion engages with narrower frames, making the corner piece universal for multiple frame types without requiring separate designs for each width.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The locking mechanism is segmented into two distinct locking protrusions positioned at different locations on the corner piece. This segmentation allows each protrusion to target specific frame width scenarios, with the first protrusion for wider frames and the second for narrower frames, thereby solving the adaptability issue through functional division.

Inventive Principle:

Principle #1Segmentation

2Stability of the object's composition

If fixing band is used to prevent shaking during transportation, then panels are secured, but frame dents occur due to direct binding

Engineering Contradiction:

Improvestability during transportationVSAvoidframe denting

Core Design Contradiction:

Stability of the object's compositionVSObject-affected harmful factors

Solution Approach 1:

The corner piece acts as an intermediary between the fixing band and the frame. Instead of the fixing band directly binding the frame (which causes dents), the corner piece receives the fixing band's constraining force and redistributes it through its structural components, including the locking protrusions and pressing pieces, thereby securing the panel while protecting the frame from damage.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The corner piece provides beforehand cushioning by positioning the support piece and pressing piece to distribute mechanical stresses before they can concentrate on the frame. The pressing piece applies controlled pressure to secure the frame in place, while the support piece provides a cushioned bearing surface, preventing direct impact and denting during transportation.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

3Object-affected harmful factors

If corrugated cardboard is placed at corners to prevent direct contact, then frame contact damage is reduced, but vibration and impact protection is insufficient

Engineering Contradiction:

Improveframe contact damageVSAvoidprotection against vibration and impact

Core Design Contradiction:

Object-affected harmful factorsVSReliability

Solution Approach 1:

The corner piece employs composite material construction, combining rigid components (for structural support and locking) with cushioning elements (for vibration and impact absorption). This composite structure integrates the protective functions of both hard and soft materials, providing comprehensive protection against frame contact damage, vibrations, and impacts that corrugated cardboard alone cannot achieve.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The corner piece implements beforehand cushioning through its integrated cushioning elements that are positioned in advance to absorb vibrations and impacts. The pressing piece and support piece are configured to distribute and dampen mechanical shocks before they reach the frame, providing reliable protection during stacking and transportation that goes beyond the temporary measure of corrugated cardboard.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

Data Source

PatentUS11870387B2Corner piece for palletization of solar cell panels

Publication Date: 2024.01.09 YOO SANG CHAE CHUNG

AI summary

Proposed is a corner piece for palletization of solar cell panels, wherein the corner piece prevents stacked solar cell panels from colliding with each other, keeps the stacked solar cell panels from being shaken or impacted, and enables a solar cell panel having a frame fabricated with two types of sides having different widths to be interlocked. The corner piece includes: a right-angled corner part covering two right-angled sides of a frame of a solar cell panel, a support piece supporting the frame thereon; a pressing piece extending inward from the right-angled corner part so as to press the frame, and having a first locking protrusion; a fixing protrusion part protruding upward from the top of the right-angled corner part; and a concave hole formed in the lower surface of the right-angled corner part so as to receive the fixing protrusion part of another corner piece for combination.