Carbon Steel Photovoltaic Frame for Thin, High-Strength Modules
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Solution Overview
Problem
The existing production process of photovoltaic frames is complex and costly, with limited strength, leading to increased thickness and weight to accommodate larger photovoltaic module sizes, which affects production efficiency and cost.
Innovation Solution
A photovoltaic frame molded from carbon steel sheet material with specific composition and processing, including a top support portion, bottom support portion, and transverse edge portion, enhancing structural strength and stability while reducing thickness and weight.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the frame thickness is increased to accommodate larger photovoltaic module sizes, then the structural strength is improved, but the weight and production cost increase
Solution Approach 1:
The patent changes the material parameter from traditional aluminum alloy to carbon steel, which has higher strength density. This allows the frame to achieve the required structural strength with reduced thickness and weight while supporting larger photovoltaic module sizes
Solution Approach 2:
The patent uses carbon steel sheet material with specific composition (carbon content 0.12%-0.25%, manganese 0.20%-0.60%, silicon 0.10%-0.50%) to create a composite structure that optimizes both strength and weight properties for the frame
2Strength
If the frame thickness is increased to accommodate larger photovoltaic module sizes, then the structural strength is improved, but the production cost increases
Solution Approach 1:
By changing to carbon steel material with optimized composition parameters, the frame achieves required strength with thinner sections, reducing material consumption and manufacturing cost while supporting larger module sizes
Solution Approach 2:
The patent applies different material compositions and thicknesses to different parts of the frame structure, optimizing strength where needed while minimizing material usage in less critical areas, thereby reducing overall production cost
3Stability of the object's composition
If the frame thickness is increased to enhance structural strength, then the stability is improved, but the production efficiency decreases
Solution Approach 1:
The patent changes to carbon steel material with higher strength density, enabling the frame to achieve required stability with reduced thickness. This thinner design reduces manufacturing time and improves production efficiency while maintaining structural stability
Data Source
AI summary
Disclosed are a photovoltaic frame and a photovoltaic module. The photovoltaic frame includes a top support portion, a bottom support portion, a transverse edge portion, a first side edge portion and a second side edge portion. The top support portion, the transverse edge portion and the second side edge portion enclose a holding slot, and the top support portion has a bearing surface facing the holding slot. The photovoltaic frame alternatively includes a third side edge portion configured to connect the top support portion and the bottom support portion. The photovoltaic frame further includes a weather-resistant protective layer, covering a part of outer surfaces, that are in contact with external environment, among the top support portion, the bottom support portion, the first side edge portion, the second side edge portion, the transverse edge portion, and the third side edge portion if included.