CN117178474A

CN117178474A - Frame for solar panels

Info

Publication number: CN117178474A
Application number: CN202280029284.XA
Authority: CN
Inventors: 约翰·C·巴顿; 埃里克·L·哈弗特; 泰勒·哈德逊
Original assignee: Origami Solar Energy Co ltd
Current assignee: Origami Solar Energy Co ltd
Priority date: 2021-04-19
Filing date: 2022-04-19
Publication date: 2023-12-05

Abstract

A frame (101) for at least partially enclosing or supporting a panel (190) is provided. The frame may comprise at least a first frame portion (201-1) comprising a bottom flange (104) provided at a base of the frame portion. A frame side wall (103) may be provided at an outer portion of the frame portion, the frame side wall being characterized by a height H extending from the bottom flange (104). A panel receiving structure (101-1) may be provided at an upper portion of the frame side wall (103), the panel receiving structure including a lower shelf (105) extending from the frame side wall. A support wall (431-1) may be provided at an inner portion of the frame portion (201-1), the support wall (i) extending between the bottom flange (104) and the frame side wall (103); (ii) Extending between a bottom flange (104) and a lower shelf (105); or (iii) satisfies both (i) and (ii).

Description

Frame for solar panels

Cross Reference to Related Applications

The present application is PCT international application entitled "frame support substructure for solar panels" filed on day 4, 2021, U.S. provisional patent application No. 63/176,824 and U.S. provisional patent application No. 63/288,556 filed on day 12, 2021, and entitled "frame for solar panels", the contents of each of which are incorporated herein by reference in their entirety.

Technical Field

The present disclosure relates to various embodiments of a frame structure for a panel, such as a solar panel.

Background

Photovoltaic solar panels for residential and commercial use are relatively large and heavy. For example, a conventional rectangular solar panel may weigh about 20kg to 30kg, have a width of about 1 meter, a length of about 1.6 meters to 2.5 meters, and a thickness of about 3cm to 5 cm. Photovoltaic solar panels can generally be multi-layer laminate structures (sometimes referred to as PV laminates) and can include photovoltaic cells encapsulated between a top glass and a protective backsheet. The solar panel may also include suitable wiring and connections so that solar generated power (typically DC) may be transmitted to a desired load, grid or energy storage unit. Although the panel has some physical toughness, it may be provided with significant additional strength by including it in the frame. The frame may allow for easy attachment of the photovoltaic solar panel to the rack. The framed PV laminate is sometimes referred to as a PV module.

The cost of solar panels has been decreasing over the years, possibly due to reduced materials and manufacturing costs, and even increased solar cell efficiency. However, in order to further expand the use of renewable solar energy, it has been desired to further reduce the cost and simplify the manufacture of the frame.

Disclosure of Invention

The application includes aspects that may be selected in different combinations based on the particular application or needs to be addressed. In various embodiments, the application may include a frame for at least partially enclosing or supporting a panel. The frame may comprise at least a first frame portion comprising a bottom flange provided at a base of the frame portion. The frame side walls may be provided at an outer portion of the frame portion, the frame side walls being characterized by a height extending from the bottom flange. A panel receiving structure may be provided at an upper portion of the frame side wall, the panel receiving structure including a lower shelf extending from the frame side wall. A support wall may be provided at an interior portion of the frame portion, the support wall (i) extending between the bottom flange and the frame side wall; (ii) extending between the bottom flange and the lower shelf; or (iii) satisfies both (i) and (ii). The bottom flange, frame side walls, lower shelf, and support wall may be formed at least in part by folds provided in a single sheet of frame material.

It is an object of the present application to provide a frame, frame part and frame precursor structure with improved frame strength.

Another object of the application may include an improved mounting structure.

Yet another object of the application may include an improved option for a high strength module.

An object of the application may include a frame, frame part and frame precursor structure having improved bending, improved torsion and even improved durability of the frame panel structure.

Another object of the application may include a frame, frame portion and frame precursor structure with reduced material costs, reduced manufacturing adhesion time and possibly even higher manufacturing yields.

Among other objects, the present application may provide a frame, frame portion, and frame precursor structure having reduced installation costs, simplified installation, reduced installation time, higher installation yields, or some other advantage.

Other objects, and embodiments of the application will, of course, be disclosed throughout the specification, claims, and other areas of the drawings.

Drawings

FIG. 1A is a plan view of a non-limiting example of a framing panel structure according to some embodiments.

FIG. 1B is a cross-sectional view of a non-limiting example of a frame panel structure along section line B-B of FIG. 1A, according to some embodiments.

FIG. 1C is a cross-sectional view from FIG. 1B, showing a non-limiting example of a frame-only according to some embodiments.

Fig. 2A is a plan view of a non-limiting example of a frame precursor structure and a panel prior to assembly of the frame panel structure, according to some embodiments.

FIG. 2B is a cross-sectional view of a non-limiting example of a frame precursor structure and panel along section line B-B of FIG. 2A, according to some embodiments.

Fig. 2C is a cross-sectional view from fig. 2B, showing a non-limiting example of a frame-only precursor structure, according to some embodiments.

Fig. 2D is a slightly elevated side view of a non-limiting example of a frame precursor structure according to some embodiments.

Fig. 2E is a plan view of a non-limiting example of a frame precursor structure and a panel at an intermediate stage of assembly according to some embodiments.

Fig. 3 is a plan view illustrating a non-limiting example of assembling a frame using four frame precursor structures, according to some embodiments.

Fig. 4A is a perspective view of a non-limiting example of a frame including a crossbar according to some embodiments.

Fig. 4B is an enlarged view of region B of fig. 4A, according to some embodiments.

Fig. 5 is a schematic diagram of a non-limiting example of a manufacturing process line for manufacturing a frame precursor structure, according to some embodiments.

Fig. 6A is a perspective view of a cut-away portion of a non-limiting example of a frame portion including a support wall, according to some embodiments.

Fig. 6B is a cross-sectional view of a frame portion from fig. 6A, according to some embodiments.

Fig. 6C is a plan view of a non-limiting example of a portion of a frame material according to some embodiments.

Fig. 6D is a cross-sectional view of a non-limiting example of a framing panel structure according to some embodiments.

Fig. 6E is similar to fig. 6B, but with a box frame of approximately closed shape marked according to some embodiments.

Fig. 6F is similar to fig. 6B, but has an approximate panel-receiving shape marked according to some embodiments.

Fig. 7A-7 OO are cross-sectional views of some non-limiting examples of frame portions according to some embodiments.

Fig. 8A is a perspective view of a non-limiting example of a frame portion to be mounted to a bracket (support structure).

Fig. 8B is a cut-away perspective view of a mounting structure according to some embodiments.

Fig. 8C is a cross-sectional view of a mounting structure according to some embodiments.

Fig. 9A is a cross-sectional view of a non-limiting example of a frame panel structure, enlarged to show a panel receiving structure portion of a frame portion, according to some embodiments.

Fig. 9B is similar to fig. 9A, but in which the sealant does not completely fill the pocket area, according to some embodiments.

Fig. 9C-9E are cross-sectional views of non-limiting examples of frame panel structures according to some embodiments to further illustrate the use of sealant within the panel receiving structure.

Fig. 10A and 10B are perspective views of some non-limiting examples of frame portions with structured lower shelves according to some embodiments.

Fig. 11A and 11B illustrate stress models of some non-limiting examples of box frames according to some embodiments.

Fig. 12A-12C illustrate stress models of some non-limiting examples of box frames according to some embodiments.

Fig. 13 illustrates a general model for understanding some aspects of the present disclosure with respect to stress.

Fig. 14A is a perspective view of a cut-away portion of a non-limiting example of a frame portion or frame precursor structure that may include a frame support sub-structure, according to some embodiments.

Fig. 14B is a perspective view of a cut-away portion of a non-limiting example of a frame portion or frame precursor structure that may include a frame support sub-structure, according to some embodiments.

Fig. 14C is a perspective view of a cut-away portion of a non-limiting example of a frame portion or frame precursor structure that may include a frame support sub-structure, according to some embodiments.

Fig. 15 is a perspective view of a cut-away portion of a non-limiting example of a frame portion or frame precursor structure that may include a frame support sub-structure, according to some embodiments.

Fig. 16A-16K are a series of various views of a non-limiting example of a frame material, showing a sequence of steps to form a frame or frame precursor structure, according to some embodiments.

Detailed Description

It should be understood that the embodiments include various aspects that may be combined in different ways. The following description is provided to list elements and to describe some of the embodiments of the present application. These elements are listed together with the initial embodiment; however, it should be understood that they may be combined in any manner and in any number to create additional embodiments. The various described examples and embodiments should not be construed as limiting embodiments of the application to only the explicitly described systems, techniques, and applications. The particular embodiment or embodiments shown are merely examples. The description should be understood and intended to support the broad claims and the claims of each embodiment, and even claims of other embodiments may be excluded. Importantly, the disclosure of only the exemplary embodiments is not meant to limit the scope of other broader claims that may be made in such circumstances, as these claims may be one of only a few of the methods or embodiments employed in the broader claims or similar claims. Furthermore, this description should be understood to support and include the description and claims of all the various embodiments, systems, techniques, methods, apparatuses and applications with any number of the disclosed elements, where each element is used alone and with any and all various permutations and combinations of all elements in the present application or any subsequent application.

It should be understood that the drawings are for purposes of illustrating the concepts of the disclosure and may not be to scale. Additional details of certain embodiments of the present application may be found in PCT application PCT/US2020/037092 (published as WO2020/252091A 1) filed on 6-10-2020, U.S. provisional application 63/176,803 filed on 4-19-2021, U.S. provisional application 63/189,591 filed on 5-17-2021, U.S. provisional application 63/213,541 filed on 6-22-2021, U.S. provisional application 63/224,271 filed on 21-2021, and U.S. provisional application 63/272,086 filed on 26-10-2021, each of which is incorporated herein by reference in its entirety.

Fig. 1A is a plan view of a non-limiting example of a frame panel structure 100 (e.g., a frame solar panel structure or PV module) including panels 190 (e.g., solar panels) encapsulated in a frame 101 according to some embodiments. Fig. 1B is a cross-sectional view of the frame panel structure 100 along section line B-B. For additional perspective, XYZ coordinate axes are also shown. Fig. 1C is the same cross-sectional view as in fig. 1B, but without the inclusion of a panel to further illustrate some features of frame 101.

In some embodiments, as discussed in more detail herein, the frame 101 may be formed from a substantially single frame precursor structure that is bent in a predetermined area to accommodate three corners of the solar panel, possibly a fourth corner forming a joint between two ends of the frame precursor structure. That is, in some cases, the frame 101 may include a first corner bend 112 corresponding to a first corner of the panel 190, a second corner bend 114 corresponding to a second corner of the panel 190, a third corner bend 116 corresponding to a third corner of the panel 190, and even a corner joint 118 corresponding to a fourth corner of the panel 190.

Referring to fig. 1B and 1C, the frame 101 may include a frame material that has been cut and folded into a desired shape. The frame 101 may be characterized by a height H and may include a longitudinal fold 102 defining the intersection of the frame side wall 103 and the bottom flange 104. The frame may also include a series of folds to form a panel receiving structure 101-1 that includes a lower shelf 105, a pocket wall 106, a top lip 107, and possibly even a pocket region 108. In some embodiments, the bottom flange may generally represent or be disposed at the base of the frame or frame panel structure. The panel 190 may be received in a portion of the pocket area and secured in place, optionally with a sealant (not shown) that may have adhesive properties. Some non-limiting examples of sealants may include curable liquid silicones, polyurethanes, epoxies, resins, any other liquid sealant, and the like. Alternatively, or in combination, pressure sensitive adhesive tape may optionally be used to secure the panel in the pocket region. In some embodiments, the panel receiving structure may include only the lower shelf, or alternatively, only the lower shelf and the pouch wall. In such embodiments, the panel may optionally be secured in place using a sealant or pressure sensitive adhesive as described above. In some embodiments, only some of the frame portions may include panel receiving structures, e.g., only frame portions on a set of opposing sides of a rectangular or square panel.

Although fig. 1B and 1C illustrate non-limiting examples in which the bottom flange, lower shelf, and top lip all extend to the same extent from the frame side walls, any of these features may vary, such as being shorter or longer than others, etc. The angle between the frame side walls and the bottom flange is shown as about 90 deg., such as in the range of about 85 deg. to about 95 deg., but in some other embodiments the angle may be outside of this range, such as in the range of about 45 deg. to about 135 deg., depending on other features of the structure and the overall system design. In some embodiments, the lower shelf and bottom flange may remain substantially parallel, for example within about 40 °, alternatively within about 30 °, 20 °, 15 °, 10 °, or 5 °, regardless of the angle between the frame side walls and the bottom flange. The top lip is shown parallel to the lower shelf, but in some embodiments it may be slightly angled or curved at the ends such that the opening of the pocket area is larger or smaller than the pocket wall. In the embodiment shown in fig. 1B and 1C, the lower shelf 105 is shown as being formed of, or including, multiple layers of framing material. In some embodiments, any or all of the frame features (e.g., side walls, bottom flange, lower shelf, pouch walls, upper lip, support wall, etc.) may be formed from or include multiple layers of frame material. In some cases, multiple layers may provide increased strength to the frame.

Fig. 1A, 1B and 1C illustrate conventional rectangular panel shapes commonly used for solar panels. However, the shape of the panel is not particularly limited, and the panel may be any shape, for example, a polygon having 3, 4, 5, 6, 7, 8 or more sides. The sides of the polygon may have the same length, or alternatively, some sides may be longer or shorter. The corner angles of the polygons may all be the same, or alternatively, some corner angles may have smaller or larger angles than other corner angles. Although the frames and frame portions shown herein generally have bottom flanges, in some embodiments, one or more frame portions may not include bottom flanges. In some embodiments where the frame has a rectangular shape, the frame portion corresponding to the shorter side of the frame may not include a bottom flange, and the frame portion corresponding to the longer side of the frame may include a bottom flange.

Manufacturing a frame or frame portion from substantially a single sheet of frame material may have considerable manufacturing, assembly and cost advantages. However, in some embodiments, the panel receiving structure may be formed using alternative methods and materials. For example, the lower shelf may include a sheet of shelf material bonded (e.g., welded, soldered, glued, riveted, etc.) to an upper portion of the frame side walls. Similarly, the top lip may comprise a top lip material sheet bonded to the top of the frame structure. Alternatively, the entire panel receiving structure may be a separate structure designed to sit on, slide over, or mate with the frame side walls. As discussed elsewhere herein, rather than one elongate piece of frame material, a 4-sided frame may be formed from 2, 3, or even 4 separate frame portions (or more, or if the frame has more than 4 sides). Although not shown in fig. 1A-1C, the frame or frame panel structure may also include support walls extending from the bottom flange to the panel receiving structure or to the frame side walls, as described in more detail elsewhere herein. It should be noted that throughout this disclosure, the upper and top lips may refer in some cases to general positions relative to the bottom flange or base of the frame, and do not necessarily indicate positions or orientations in the final frame panel structure, which may be oriented in a different manner (e.g., at an angle, on a side thereof, or even top side or completely inverted) than horizontal as shown in fig. 1B.

Fig. 2A is a plan view generally illustrating the construction of a framing panel structure according to some embodiments. Fig. 2B is a cross-sectional view of fig. 2A along section line B-B. The frame precursor structure 201 can be formed from a frame material characterized by an average thickness. The frame precursor structure 201 can include a first end 210 and a second end 220 defining a longitudinal dimension. The frame precursor structure 201 can include a first frame portion 201-1 designed to mate with the first panel edge 190-1 of the panel 190 or attach to the first panel edge 190-1 of the panel 190, a second frame portion 201-2 designed to mate with the second panel edge 190-2 or attach to the second panel edge 190-2, a third frame portion 201-3 designed to mate with the third panel edge 190-3 or attach to the third panel edge 190-3, and even a fourth frame portion 201-4 designed to mate with the fourth panel edge 190-4 or attach to the fourth panel edge 190-4. The frame precursor structure 201 can include a first corner bending precursor axis 212 between the first frame portion and the second frame portion, and can be designed to bend along the Z-axis (height axis) of the frame sidewall. In the finished frame panel structure, the first corner bend precursor axis 212 may correspond to the first corner bend 112 (fig. 1A). Similarly, the frame precursor structure 201 can include a second corner curved precursor axis 214 and a third corner curved precursor axis 216, respectively.

Referring to fig. 2B, the cross-sectional structure is related to the cross-sectional structure of fig. 1B for the finished frame. Fig. 2C is a cross-sectional view as in fig. 2B, but without including a panel, to further illustrate some non-limiting examples of features of the frame precursor structure, particularly frame portion 201-2. Here, the second frame portion 201-2 may be characterized by a height H and may include a longitudinal fold 202-2 that may define an intersection of the frame sidewall 203-2 and the bottom flange 204-2. The second frame portion may include a series of folds to form a panel receiving structure including a lower shelf 205-2, a pocket wall 206-2, a top lip 207-2, and possibly even a pocket area 208-2. In some embodiments, the bottom flange may generally represent or be disposed at the base of the frame portion. The panel edge 190-2 of the panel 190 may be received into a portion of the pocket area and optionally secured in place with some sealant (not shown). In some embodiments, each frame portion of the frame precursor structure may have substantially the same cross-sectional structure as shown in the second frame portion 201-2 in fig. 2B. In some other embodiments there may be differences between the cross-sectional structures of two or more of the frame portions. In the embodiment shown in fig. 2B and 2C, the lower shelf 205-2 is shown as being formed of or including multiple layers of frame material. In some embodiments, any or all of the frame portion features (e.g., side walls, bottom flange, lower shelf, pocket wall, upper lip, support wall, etc.) may be formed from or include multiple layers of frame material. In some cases, multiple layers may provide increased strength to the frame.

To accommodate bending of the frame precursor structure to enclose the panel, the frame precursor structure may include a series of notches (212N, 214N, 216N) in the top lip, lower shelf, and even bottom flange, corresponding to the first corner bending precursor axis 212, the second corner bending precursor axis 214, and the third corner bending precursor axis 216, respectively. In FIG. 2A, the notch is only visible in the top lip (between top lip 207-1 and top lip 207-2, between top lip 207-2 and top lip 207-3, and between top lip 207-3 and top lip 207-4), but similar notches may also be present in the lower shelf and bottom flange. In some embodiments, the angle of the notch may be about 180 ° minus the angle of the enclosed panel corner. Similarly, the ends of the frame precursor structure may also include angled cuts (210N and 220N) in the top lip, lower shelf, and bottom flange to accommodate the formation of corner joints.

In fig. 2D, a non-limiting example of a schematic side view (slightly raised) of the side of the frame precursor structure facing the side where the panel can be accommodated is shown. For clarity, not all features are labeled, but rather, in combination with other figures, the identification of each feature is apparent.

Referring to fig. 2E, a plan view of a non-limiting example of an intermediate state of assembly of a frame panel structure is shown, wherein the frame precursor structure has received the panel edge 190-2 into the frame portion 201-2 and forms a bend along the bending precursor axis as the other frame portions move closer to their intended final positions about the panel. Note that the assembly need not start from panel edge 190-2, but may start from any panel edge or corner. The corner joints 118 (see fig. 1A) that form the intersection of the two ends (210 and 220) of the frame precursor structure may be the final step in this portion of the frame panel structure assembly, but there may be additional steps to further secure or modify the frame (e.g., adding optional support brackets, tightening optional bolts, etc.). In some embodiments, assembling the frame panel structure may include an assembly apparatus using the holding and manipulating panel and the frame precursor structure. With respect to the orientation of the components relative to the assembly device during assembly, the plan view of fig. 2E may represent a view from above, or alternatively a view from below, or even a view from the side, depending on the nature of the assembly device.

In some embodiments, the corner bends and/or corner joints may include features that enable the formation of interlocking structures. For example, the bottom flange or other portion on one side of the corner may include a locking element that may be received in an opening on the other side of the corner.

Although not shown in fig. 2A-2E, one or more frame portions may also include support walls extending from the bottom flange to the panel receiving structure or to the frame side walls, as described in more detail elsewhere herein.

In some embodiments, the frame precursor structure 201 may be substantially linear (as shown) prior to assembly of the frame panel structure. In some embodiments, the frame precursor structure may be received by an assembler that has been partially bent at one or more corner bending precursor axes. One or more corner bend precursor axes may be pre-scored or include grooves or features that facilitate bending along a height channel between frame portions.

The frame and frame precursor structures described in fig. 1A-1C and 2A-2E are non-limiting examples provided to illustrate how some of the frame support sub-structures and frame support walls described below may be implemented in a frame. Alternative designs and structures may be effectively used with such support structures. In some embodiments, rather than using one frame precursor structure, multiple frame precursor structures may be used to enclose the panel. For example, for a rectangular panel, two similar frame precursor structures, each having one corner bending precursor axis, may be used to form a frame panel structure that may include two corner joints at opposite corners and two corner bends at opposite corners. Alternatively, the first frame precursor structure may have two corner bend precursor axes, while the second frame precursor structure may have no corner bend precursor axes, and is used to form a frame panel structure that may include two corner joints at adjacent corners and two corner bends at adjacent corners. Alternatively, three frame precursor structures may be used, one of which may have one corner bend precursor axis and the other two may have no corner bend precursor axis, whereby the frame panel structure may comprise one corner bend and three corner joints. Alternatively, four frame precursor structures may be used, none of which have corner bending precursor axes, and the frame panel structure may include four corner joints.

Fig. 3 is a plan view illustrating a non-limiting example of assembling a frame using four frame precursor structures, according to some embodiments. Each frame precursor structure (each of which may also be referred to herein as a frame portion) 301-1, 301-2, 301-3, 301-4 may optionally include any of the features described above, such as a bottom flange, side walls, and even a panel receiving structure that may include a lower shelf, a pocket wall, and a top lip. In some cases, one or more of the frame portions may also include a support wall extending from the bottom flange to the panel receiving structure or to the frame side wall, as described elsewhere herein. In this view, only the top lip 307-1, 307-2, 307-3, 307-4 of each frame precursor structure is visible. Each frame precursor structure can have a first end 310-1, 310-2, 310-3, 310-4 and a second end 320-1, 320-2, 320-3, 320-4. When assembled, the first end of one frame precursor structure may form a corner joint with the second end of an adjacent frame precursor structure. As discussed with respect to fig. 2E, the plan view of fig. 2E may represent a view from above, or alternatively a view from below, or even a view from the side, depending on the nature of the assembled device.

As indicated by the arrows, the first frame precursor structure may be designed to mate with the first panel edge 190-1 of the panel 190 or attached to the first panel edge 190-1 of the panel 190, the second frame precursor structure 301-2 may be designed to mate with the second panel edge 190-2 or attached to the second panel edge 190-2, the third frame precursor structure 301-3 may be designed to mate with the third panel edge 190-3, and even the fourth frame precursor structure 301-4 may be designed to mate with the fourth panel edge 190-4. There are many variations regarding the sequence for assembling the frames. In some embodiments, all four frame precursor structures may be simultaneously bonded together with their respective panel edges and attached substantially simultaneously. In some cases, the attachment is sequential, and may be performed in any order. In some embodiments, only two or three frame precursor structures are bonded together simultaneously with their respective panel edges, and the remaining frame precursor structures are later attached or have been pre-attached. In some embodiments, two or three of the frame precursor structures may be attached to each other first by corner joint connections and then to the panel. In some cases, the frame precursor structures may be initially joined together at an angle to their respective panel edges rather than flush or parallel. In some cases, the selection of the assembly sequence may depend in part on the design of the corner joint and optional corner joint connection used. In some embodiments, the corner joint connection may be made, for example, using rivets, screws, nuts/bolts, welding, adhesives, and the like. In some cases, the corner joint connection may be made using the tab connection assembly discussed in U.S. provisional patent application 63/272,086, filed on 10/2021, or any other connection structure and method.

In some embodiments, the finished frame (whether made of a continuous piece or of multiple frame section pieces) may also include one or more rails that may extend from one frame section to an opposing or adjacent frame section. In some embodiments with respect to a rectangular frame, the cross bar may extend between two longest opposing frame portions. In some cases, the crossbars may connect two opposing frame portions near their intermediate regions. The cross bars may act as reinforcing frames. The rails may be connected to the frame at the bottom flange, at the frame side walls, or at some other frame feature, including but not limited to support walls (discussed below). In some embodiments, the rail structure may include an upper surface upon which the panel may rest or alternatively be adhered. In some cases, the cross bar may be easily attached as part of the panel mounting process (e.g., as discussed in fig. 2E and 3). That is, in some cases no additional separate step may be required. In some embodiments, the cross bar may be formed from a frame material for the remainder of the frame. In some embodiments, the cross bar may use different materials.

Fig. 4A is a perspective view of a non-limiting example of a frame including a crossbar according to some embodiments. For clarity, the frame panels are not shown. In some cases, the frame 401 may include a first frame portion 401-1, a second frame portion 401-2, a third frame portion 401-3, and even a fourth frame portion 401-4. The crossbar 460 may be connected to the opposing frame portions 401-1 and 401-3. In some embodiments, the connection may be made, for example, using rivets, curls, rivets, screws, nuts/bolts, welding, adhesives, and the like. In some cases, the connection may be made using the tab connection assembly discussed in U.S. provisional patent application 63/272,086, filed on 10/2021, 26, or any other connection structure and method.

Fig. 4B is an enlarged view of region B of fig. 4A. In some cases, the first frame portion 401-1 may optionally have a box frame structure as described below. For example, frame portion 401-1 may include a bottom flange 404-1, a support wall 432-1, a lower shelf 405-1, a top lip 407-1, and frame side walls (not visible in this view). In some embodiments, crossbar 460 may include a crossbar top surface 465 and a crossbar side wall 463. Crossbar 460 may optionally have a box-type structure that includes another side wall opposite crossbar side wall 463 (not visible in this figure) and a bottom flange or bottom surface (not visible in this figure) opposite crossbar top surface 465. In some cases, the rail top surface 465 may contact the panel and may optionally include an adhesive layer to help secure the panel. In some embodiments, the rail top surface 465 may be flush (e.g., at the same height) with the lower shelf 405-1 of the first frame portion. In some embodiments, the crossbar 465 may be connected to the first frame portion at a frame side wall, a bottom flange, a support wall, or any combination.

The framing material should have sufficient strength to support the panels. In some embodiments, the frame material may include a metal, such as uncoated steel, coated steel, stainless steel, aluminum, or another metal or metal alloy (possibly coated or uncoated), and the like. In some embodiments, the frame material may be a coated metal, such as coated steel, including a corrosion resistant coating or treatment. For example, the coated steel may comprise a metal coated steel, an organic coated steel, or a tin plate. Some non-limiting examples of metal coatings for steel may include zinc and zinc alloys (e.g., zn-Al alloys), aluminum, magnesium, and the like. Depending on the coating, such a metal coating may be applied by hot dip galvanization, electro galvanization, thermal spraying, etc. Some non-limiting examples of organic coatings may include polyester or PVDF, which may be applied from paint or other mixtures that may be applied. Tin-plated plates may be manufactured by coating tin onto cold rolled steel, for example by electroplating. In some embodiments, the thickness of the coated steel used as the framing material may be in the range of about 0.5mm to about 0.6mm, alternatively about 0.6mm to about 0.7mm, alternatively about 0.7mm to about 0.8mm, alternatively about 0.8mm to about 0.9mm, alternatively about 0.9mm to about 1.0mm, alternatively about 1.0mm to about 1.2mm, alternatively about 1.2mm to about 1.4mm, alternatively about 1.4mm to about 1.6mm, alternatively about 1.6mm to about 1.8mm, alternatively about 1.8mm to about 2.0mm, or any combination or permutation of the ranges thereof, and the like. While the coated steel frame material may be used to fabricate frames for conventional photovoltaic solar panels, in some embodiments, the thickness may be in the range of about 0.7mm to about 1.4 mm.

In some embodiments, the steel may be a steel other than stainless steel. For some applications, such as for photovoltaic solar panels, steel may have a useful combination of technical and commercial benefits. The steel may have properties that may be useful for material selection, manufacturing, and long-term durability, which are useful for the form and function of the frame or frame precursor structural product. During pre-production, the steel can be readily coated with a corrosion resistant coating that uses a variety of chemicals that provide corrosion resistance that can be beneficial to the durability of the frame. The steel may be painted a clear or specific color that may optionally allow for identification of specific module choices for the various categories. Because paints or corrosion resistant coatings can be applied in high speed manufacturing, cost and durability are more efficient than most other metals. The steel may optionally be painted and have a corrosion resistant coating that allows for a variety of benefits to marking of non-steel module frames, module identification, and long-term maintenance.

Steel is a highly durable material that can be significantly deformed while retaining its toughness and resistance to structural failure. The property of toughness upon deformation may be referred to as ductility. Due to the ductility of the steel, it may be formed starting from a sheet material, for example wound on a roll, which may be fed directly to a stamping station, which may cut or partially cut or create grooves in the surface of the steel sheet in a number of ways. After this process, the steel that has been modified in the stamping station can be fed into a linear and non-linear set of rollers that can deform the steel sheet into a new profile with many possibilities for variation. Because of the ductility of the steel, the process can be performed at high speeds, ranging from less than about 0.1 meters per second to greater than about 4.0 meters per second. The compatibility of steel with such high speed forming processes can provide significant manufacturing cost advantages. Due to the ductility of the steel, it can be bent into a simple or complex shape, which will maintain its relative shape or position over the life of the product. In some embodiments, steel that has been formed into a simple or complex form may also be designed to yield or partially yield at a particular location or along a predetermined path as part of the intended installation or operating parameters.

The steel has electrical characteristics that may allow it to act as a canonical approval path for the intended power, e.g., creating an electrical ground or electrical bond. Due to the properties of the steel and the corrosion-resistant or paint coating that may be present, electrical grounding or electrical bonding may still occur without the need for additional hardware or equipment. Most electrical specifications allow such connections to be considered as effective electrical grounding or electrical bonding when the steel module frame is directly attached to the steel structure. This means that the frame panel structure can be directly connected to the steel substructure and can be considered to have achieved sufficient electrical grounding or electrical bonding to meet the specifications as part of the module-to-substructure attachment, with or without the addition of hardware.

The magnetic properties of steel can provide special features and benefits through the use of a magnetic steel frame. The magnetic properties of steel may allow for simple attachment of accessories with little or no additional hardware. The magnetic properties of the steel may allow the sensing device to collect useful data or data about the panel mounting during fabrication of the frame precursor structure. The magnetic properties of the steel may allow the robotic sensor to be used to aid in the proper installation or removal of the panel module. The magnetic properties of steel may allow various types of hardware to be easily attached or pre-attached to the module frame to facilitate installation of additional equipment.

In some cases, the frame precursor structure may be made from an elongated sheet of bendable and cuttable frame material. For example, depending on the frame material, a water cutter, laser, punch, saw, etc. may be used to cut the elongated sheet. The cutouts may be used to form some of the various features described herein, such as notches, holes, grooves, or other features. After at least some of the cuts are made, the elongated sheet may be folded to form at least a portion of the frame precursor structure. Such folding may include, but is not limited to, roll forming. In some embodiments, the cutting and folding process may be applied to a coated steel-based framing material.

Fig. 5 is a schematic diagram illustrating a non-limiting example of a manufacturing process line for manufacturing a frame precursor structure, according to some embodiments. The manufacturing process line 500 may include a framing material station 510 with framing material that may be fed to a next station. In some embodiments, the framing material may be in the form of a sheet pre-cut to a final desired length. In some embodiments, the frame material may be continuously fed to the next station. For example, the framing material station 510 may include a roll 512 of coated steel 514. The coated steel 514 may be supplied to a stamping station 520. For example, the stamping station 520 may pull the coated steel 514 from a roll. In some embodiments, certain cutting and/or stamping processes may be performed at stamping station 520 to cut and/or remove predetermined portions of the frame material to produce a patterned frame material. In some embodiments, if such a cut has not been made, the frame material may be cut to the desired length at the stamping station. In some implementations, the process may be controlled to a high tolerance. The stamping station 520 may include a microprocessor 525 and machine software and/or firmware that may control the cutting. The stamping station 520 may include one or more sensors 526 that provide data to a microprocessor that may be used to monitor the stamping process or identify defects. The microprocessor 525 may be in electronic communication with an external computer for sending or receiving data or instructions or with another microprocessor. Such electronic communication may be via cable or wireless means.

After the stamping station 520, the patterned frame material, such as coated steel or the like, may be received by a roll forming station 530. The steel may be formed in a linear fashion using a plurality of rollers that provide a staged bending process to form the steel into a desired shape, such as a formed frame material. The design of the rolls, the order of the rolls and the tolerances can be highly accurate and can result in a fully or even almost fully formed and stamped frame precursor structure. The roll forming station 530 may include a microprocessor 535 that may control roll forming, machine software and/or firmware. The roll forming station 530 may include one or more sensors 536, the sensors 536 providing data to a microprocessor that may be used to monitor the bending and folding process or identify defects. The microprocessor 535 may be in electronic communication with an external computer for sending or receiving data or instructions or with another microprocessor. Such electronic communication may be via cable or wireless means. In some embodiments, if such a cut has not been made, the framing material may be cut to the desired length at the roll forming station. In some embodiments, the roll forming station may include an adhesive application tool to apply an appropriate adhesive to a predetermined portion of the frame material while forming the frame material, for example, to assist the formed frame material in maintaining its shape.

After the roll forming station 530, the formed framing material (e.g., coated steel) may be received by a post forming station 540. Some non-limiting examples of post-forming processes may include cutting the frame precursor structure to length, polishing/deburring, cleaning, or passing the frame precursor structure through straightening rollers or dies that may ensure product accuracy. Post-forming station 540 may include machine software and/or firmware and a microprocessor 545 that may control one or more post-forming processes. The post-forming station 540 may include one or more sensors 546 that provide data to a microprocessor that may be used to monitor the post-forming process or identify defective or out-of-tolerance parts. These data may be fed back to the roll forming station 530 for active adjustment of the roll forming rolls or the conditioning rolls. The post-forming station 540 may include a cleaning section. The microprocessor 545 may be in electronic communication with an external computer for sending or receiving data or instructions, or with another microprocessor. Such electronic communication may be via cable or wireless means.

After the post-forming station 540, the finished or even near-finished frame precursor structure 560 is received by the finishing station 550. The frame precursor structure may be loaded into a shipping container and ready for delivery to, for example, solar panel module production equipment.

In some embodiments, the framing material may be performed in a generally linear or forward direction from one station to the next. In some embodiments, the orientation of the framing material may be temporarily reversed within the station, for example, to repeat a particular step. In some embodiments, there may be multiple stamping stations, roll forming stations, and/or post forming stations.

For any of the above stations, the microprocessor may provide control signals to an electromechanical motor, which may be responsible for moving the intermediate product along the production line. Depending on the process to be performed on the intermediate product, the software/firmware running on the microprocessor may dictate various factors/parameters of the product. For some non-limiting examples only, the microprocessor may dictate the speed and/or direction of the intermediate product through a given station. In some embodiments, the microprocessor may dictate when and/or how intermediate products are shaped, perforated, cut, etc. to affect the desired intermediate/final product. In some embodiments, the microprocessor may receive signals from one or more sensors for monitoring the manufacturing process, identifying defective or out-of-tolerance parts, or measuring some other useful property of the intermediate product as it is manufactured. For example, an optical or imaging sensor may provide data that allows a microprocessor to evaluate manufacturing conditions and/or perform certain manufacturing steps. In some embodiments, if the quality is below the standard, the microprocessor may send a status alert signal to the system operator and/or to another microprocessor. Other sensors may also be used to monitor manufacturing conditions and/or quality control metrics. Non-limiting examples of potentially useful sensors or components thereof, in addition to optical and imaging sensors, may include laser-based sensors (including but not limited to laser position sensors), vision systems (including but not limited to vision measurement and shape vision systems), contact sensors (including but not limited to contact position sensors), vibration sensors, thermal sensors, conductivity sensors, roughness sensors, profilers, ultrasonic sensors, stress sensors, and the like.

In some embodiments, the frame or frame panel structure may be attached to a support structure that may hold the frame or frame panel structure in a predetermined position. Such support structures and systems may take a variety of forms, but some non-limiting examples may include brackets, track mounts, rod mounts, track mounts or non-track mounts, and the like. In combination with the support structure, the frame or frame panel structure may be attached to its intended purpose, including but not limited to attachment to a building (e.g., roof, wall, canopy, etc.), ground, shade structure or conveyance or a moving or stationary vehicle. In some embodiments, the frame or frame panel structure may be directly attached to its intended purpose without an intermediate support structure. In this case, the target itself may serve as the support structure.

To provide strong support and strength to a frame panel, such as a solar panel, for example, it may be useful for the frame to include one or more attachment features when forming a corner joint between frame precursor structures or portions. To describe the various connection features and techniques below, the frame precursor structure and frame portions may be used interchangeably unless otherwise indicated. In some cases, the frame may also include additional stiffening features, such as crossbars that may extend from one frame portion to an opposing or adjacent frame portion. These additional reinforcing features may also benefit from the use of one or more connection features. Similarly, in some embodiments, certain connection features may be used to attach the frame panel structure to a support structure, such as a bracket.

Frame support substructure

In some embodiments, the frame or frame portion shown in fig. 1-3 may benefit from additional structural support features, such as a frame support substructure, which may improve the strength of the frame in some manner to account for various forces that may be experienced when used in a frame panel structure. For example, such additional support may enable the frame to hold larger panels (e.g., PV laminates), to withstand larger environmental and/or handling forces (e.g., wind, snow, installation, clamping, bending, torsional stresses, etc.), or to increase PV module life by reducing the number or strength of stress points or improving their distribution. In some cases, the structural support features may enable the use of thinner, easier to handle, or cheaper frame materials.

In some embodiments, useful structural support features, such as a frame support substructure, may include a support wall (i) extending between the bottom flange and the frame side wall; (ii) extending between the bottom flange and the lower shelf; or (iii) satisfies both (i) and (ii). In some cases, the frame or frame portion including the support wall, bottom flange, side walls, and lower shelf may advantageously be made from a single sheet of frame material. In some cases, using a single sheet of frame material for these features may simplify manufacturing, thereby reducing costs and increasing throughput and yield. Such single piece fabrication may also increase the life of the frame by avoiding the many failure prone connection points that would be required if these features were assembled from separate parts.

Many embodiments of useful frame portions include support walls. Fig. 6A is a perspective view of a cut-away portion of a non-limiting example of a frame portion including a support wall, according to some embodiments. The height H and longitudinal L axes are also shown for reference. Fig. 6B is a cross-sectional view of the frame portion from fig. 6A, but labeled in a modified manner to illustrate that any feature may include multiple layers of frame material. The frame portion 601 may comprise a frame material that has been cut and folded into a desired shape. The frame portion 601 may include a bottom flange 604 disposed at a base of the frame portion, and in some embodiments, the bottom flange 604 may include multiple layers of frame material, such as bottom flange layers 604' and 604". The frame side walls 603 may be provided at an outer portion of the frame portion and characterized by a height extending from the bottom flange. In some embodiments, the longitudinal fold 602 may define an intersection of the frame sidewall 603 and the bottom flange 604, e.g., an intersection with the bottom flange layer 604'. The panel receiving structure may be disposed at an upper portion of the frame sidewall. The panel receiving structure may include at least one lower shelf 605 extending from the frame side wall and may also include a pocket wall 606, a top lip 607, and possibly even a pocket region 608 for receiving a panel. In some embodiments, some or all of the lower shelf 605 may include multiple layers of frame material, such as lower shelf layers 605', 605", 605'". In some embodiments, two or more lower shelf layers may be formed from folds in the frame material at the upper portions of the frame side walls. In some cases, lower shelf layers 605 "and 605 '" formed by folds in the frame material at the upper portions of the frame side walls may be characterized as panel receiving support features on which lower shelf layer 605' is located. In some embodiments, the top lip may be formed from multiple layers of frame material, such as top lip layer 607' and top lip layer 607", which may be formed from top lip folds 637 to form multiple layers of rounded top lip edges. The support wall 632 may be disposed at an interior portion of the frame portion (relative to an interior portion of the frame side wall). In some embodiments, the support wall 632 may extend between the bottom flange and the lower shelf. In some embodiments, the frame portion may include a reverse flange fold 639 such that the bottom flange portion 604' may include a double layer of frame material. In some embodiments, another longitudinal fold 631 may define an intersection of the support wall 632 and the bottom flange structure (e.g., with the portion 604'). In some cases, the longitudinal fold 633 may define an intersection of the support wall with the lower shelf 605.

Fig. 6C is a plan view of a non-limiting example of a portion of frame material 640 prior to any cutting, stamping or folding operations that may be used to fabricate frame portion 601. The longitudinal dimensions of the frame material are shown as a first edge E1 and a second edge E2, which are also marked in fig. 6A and 6B. In some embodiments, as shown in fig. 6A and 6B, E1 may correspond to an end of the top lip layer 607", while E2 may correspond to an end of the lower shelf layer 605'.

Fig. 6D is a cross-sectional view of a non-limiting example of a framing panel structure according to some embodiments. The frame panel structure 600 may include various frame portions as described above, such as frame portion 601-2 and opposing frame portion 601-4. In some embodiments, each frame portion may include frame side walls 603-2, 603-4, bottom flanges 604-2, 604-4, lower shelves 605-2, 605-4, pocket walls 606-2, 606-4, top lips 607-2, 607-4, and support walls 632-2, 632-4. The panel 690 may be received in a portion of each pocket area (formed by the lower shelf, pocket wall and top lip) and secured in place, optionally with a sealant (not shown) that may have adhesive properties. The frame side walls of the frame parts may be characterized as being arranged at the outer parts of the frame parts, while the support walls of the same frame parts may be characterized as being arranged at the inner parts of the frame parts. In some embodiments, the outer portion may include a location in relation to the support wall, and the frame side wall may be generally disposed away from the center of the panel. In some embodiments, the inner portion may be related to the frame side wall location and the support wall may be disposed generally closer to the center of the panel. The outer and inner portions may be relative terms in relation to the frame side walls and support walls and do not necessarily mean the outermost or innermost portions of the frame portions (although this may be the case in some embodiments).

A frame or frame precursor structure having a frame portion similar to that of fig. 6A or 6B may sometimes be referred to herein as a box frame, wherein the bottom flange, frame side walls, lower shelf and support wall collectively form a closed structure in cross section, in this case having four sides. However, the box frame may be applied to any frame portion forming any closed shape in cross section. In some embodiments, the closed shape may include at least a bottom flange, a frame side wall, and a support wall, and have three or more distinct sides in cross-section.

As described above, there are various alternative embodiments of the box frame in addition to those shown in fig. 6A-6B. Fig. 7A-7 OO are cross-sectional views of some non-limiting examples of frame portions according to some embodiments. For clarity, these drawings are not generally labeled with part numbers, but rather, the identification of their various framework features is apparent from the other drawings and discussion herein. The box frame, including but not limited to the box frame shown herein, may have one or more of the following advantages: improved load distribution; improved strength for use with top clamps when mounted to a bracket; improved torsional stiffness; improved flexural rigidity; improved manufacturability; or some other advantage. As described elsewhere, wherever layers of framing material intersect, attachment features may optionally be provided to bond or otherwise hold the layers together. In some cases, particularly useful but still optional attachment feature locations may be highlighted in the figure by asterisks. Some non-limiting examples of attachment features may include rivets, curls, rivets, screws, nuts/bolts, welding, adhesives, and the like. In some cases, the attachment feature may include an interlocking element between two layers of framing material. In case such interlocking elements are at least partly prefabricated in the frame material, such as during roll forming and/or stamping, such attachment features may be locking features. In some embodiments, the locking features may include holes, hooks, plugs, tabs, spring tabs, etc., formed in the frame material. In some cases, the connection between the layers may be accomplished using the tab connection assembly discussed in U.S. provisional patent application 63/272,086, filed on 10/2021, or any other connection structure and method. Some of these figures and attachment features will be discussed in more detail below, but it is first useful to provide some additional non-limiting general discussion of some frame portion features.

Bottom flange

In some cases, the base of the frame portion may generally correspond to the portion of the frame portion that is below the lower shelf. In some embodiments, a bottom flange may be provided at the base of the frame. In some embodiments, the base and/or bottom flange of the frame portion may correspond to or include the lowermost portion of the frame portion. In some cases, the lowermost portion may correspond to the portion of the frame that is separated from the panel plane or the portion of the frame that is furthest from the intended panel plane. In some embodiments, the bottom flange may rest or be mounted on a support structure or bracket (not shown here). The bottom flange may comprise a single layer of frame material (e.g., fig. 7D, 7Z, 7 AA), or alternatively, two or more layers of frame material (e.g., fig. 6A, 6B, 7A-7C, 7E-7Y, 7 BB-7 OO), which may be referred to as a bottom flange layer. Fig. 7J may show fingers and crimps 1900, fig. 7N may show a continuous crimp 1901, fig. 7P may show a panel 1902, fig. 7P may show wires 1903, and fig. 7S may show finger connections 1904. For example, referring to fig. 6A and 6B, bottom flange 604 may collectively include bottom flange layers 604' and 604". In some embodiments, multiple bottom flange layers may provide improved frame strength and resistance to deformation by external forces.

Although the panels are not shown in fig. 6A-6B or fig. 7A-7 OO (except fig. 7O), in some embodiments the bottom flange may generally lie in a plane that may be substantially parallel to the panels, i.e., within about 30 °, or alternatively within about 20 °, about 10 °, about 5 °, or the like. Although shown as being generally flat, in some embodiments, the bottom flange may be curved upward or downward or partially curved. Alternatively, the bottom flange may have or include a "V" shape, an inverted "V" shape, a corrugated shape, or one or more steps. In some cases, such a shape may be beneficial when mating the frame with a bracket having a complementary/receiving surface to such a bottom flange shape.

In some embodiments, the bottom flange may extend only between the frame side wall and the support wall (e.g., fig. 7D, 7Z, 7 AA), for example, not beyond them. The bottom flange or even a portion of the bottom flange may extend between the frame side walls and the support wall and may alternatively be referred to as a box floor. In some embodiments, the bottom flange may extend past the support wall, for example, inwardly toward the center of the panel (perhaps inwardly). In some cases, the end of the inwardly extending portion of the bottom flange may include or be formed from a reverse fold (e.g., 639 in fig. 6A, or as in fig. 7A-7C, 7E-7L, 7N, 7O, 7Q-7Y, 7CC, 7 FF-7 LL, 7NN, 7 OO). In some cases, the ends of the inwardly extending portions of the bottom flange may include or be formed from both ends of the frame material (e.g., fig. 7M, 7P, 7BB, 7DD, 7EE, 7KK, 7 MM). In some embodiments, the bottom flange may extend past the frame side wall, for example outwardly away from the panel (possibly referred to as an outward extension). In some cases, the end of the outwardly extending portion of the bottom flange may include or be formed by a reverse fold (e.g., fig. 7U, fig. 7W). In some cases, the ends of the outwardly extending portions of the bottom flange may include or be formed from two ends of the frame material (e.g., fig. 7V). In some embodiments, the outward extension of the bottom flange may provide a useful interface with a clip that may be used to attach the frame to a support structure such as a bracket (e.g., fig. 7U, 7V, 7W).

In some embodiments, the bottom flange may include a frame layer that is partially wrapped or formed into a jelly roll feature, such as a roll structure (e.g., fig. 7T, 7V) that may improve frame strength or resist external forces. In some cases, the roller structure may better distribute localized forces over the entire length of the bottom flange. In some cases, the roller structure may include two edges of the frame material. In some embodiments, the bottom flange may include an upwardly or downwardly curved end (e.g., fig. 7L, 7P, 7V, 7W, 7 KK). In some embodiments, the bottom flange may include features that may act as a stop to reduce or prevent sliding of the support wall (e.g., fig. 7E, 7L, 7P, 7 KK). As shown in the various non-limiting sets of drawings, any portion of the bottom flange may include any number of shapes that may serve various functions, such as for improving frame strength, managing wires, connecting with brackets, simplifying manufacturing, reducing the need for connection/attachment features, or some other function.

In some embodiments, the bottom flange may optionally include one or more openings or other features to facilitate mounting to brackets, managing wires, tool access, forming corner joints, and the like. Fig. 8A is a perspective view of a non-limiting example of a frame portion mounted to a bracket (support structure). In some embodiments, the frame portion 801 may include a bottom flange 804, frame side walls 803, support walls 832, a lower shelf 805, a pocket wall 806, and a top lip 807. The bottom flange 804 may include an aperture 821, such as a slot. In some cases, the bottom flange may also include roller structures 804R or other multi-layer features that may help strengthen the frame and/or help mount to, for example, a bracket. In some cases, the bracket 873 can include attachment features 880 in the bracket top surface 877. For example, the attachment feature may be a tab, such as a spring tab, that may include a bendable portion 881 that extends at an angle from the plane of the tab. The hole 821 in the bottom flange 804 may be aligned with the spring tab and then brought together (as indicated by the arrow). The flexible portion of the spring tab is bent to be sufficiently straightened to pass through the aperture and can spring back to its previous position or near to the previous position and engage the bottom flange to help lock the structure in place. In some cases, the bottom flange may optionally include multiple layers of features, such as roller structures, or some other feature to help engage the spring tab. The bracket 873 may also include one or more bracket sidewalls 878. Fig. 8B is a cutaway perspective view and fig. 8C is a cross-sectional view of a mounting structure according to some embodiments. In some cases, the roller structure may better distribute the force from the spring tab, which may be localized, over the length of the bottom flange, which reduces the chance of the spring tab perforating or deforming the bottom flange. Fig. 8A-8C illustrate a non-limiting example in which holes in the bottom flange are provided in an inwardly extending portion of the bottom flange. Alternatively, or in addition, in some cases, holes may be provided in the outward extension of the bottom flange. For example, referring to fig. 7V, an aperture may be provided in the bottom flange between the roller structure and the frame side wall that may engage the bracket spring tab in a manner similar to that discussed with reference to fig. 8A-8C.

The above figures generally illustrate a bottom flange formed by a longitudinal fold in a frame material defining at least a portion of the bottom flange and a frame side wall. In some cases, this may be advantageous over embodiments in which, for example, the ends of the frame material corresponding to the bottom of the frame side walls intersect the bottom flange. In some cases, such advantages may include simpler manufacturing, improved frame strength, or ability to resist external forces. However, such longitudinal folds need not form an effective frame, and embodiments without such folds are included in the present disclosure. In some cases, embodiments without such longitudinal folds may benefit from additional features to ensure that the frame side walls do not slide relative to the bottom flange. For example, the bottom flange may include an aperture and the bottom of the frame side wall (corresponding to one end of the frame material) may include teeth or similar features that mate with the aperture. Other connection or attachment features may also be used.

Side wall of frame

The frame side walls may correspond to outer portions of the frame portions. As discussed, the outer portion may be related to the support wall and does not necessarily mean outermost. Some non-limiting examples of frame side walls corresponding to the outer portions but not outermost can be seen in fig. 7L, 7M, 7DD, 7OO (where the pocket-like wall may be outermost) and 7U, 7V, 7W (where the bottom flange may be outermost). The frame side walls may be characterized as extending a height from the bottom flange, and in some cases, to the periphery of the panel receiving structure, such as the lower shelf. In some embodiments, the upper portion of the frame side wall may include one or more folds (e.g., fig. 6A, 6B, 6D, 7A-7F, 7I-7N, 7Q, 7R, 7U-7Z, 7B, 7DD, 7II, 7NN, 7 OO) that form the lower shelf or a portion thereof. In some embodiments, the frame material forming the frame sidewalls may extend upwardly beyond the lower shelf without bending to form a pocket-like wall (e.g., fig. 7G, 7H, 7O, 7P, 7T, 7AA, 7CC, 7EE, 7 FF-7 HH, 7 JJ-7 MM). In some embodiments, the frame material forming the frame side walls may terminate at an intersection with the lower shelf, for example, as shown in fig. 7S. Although not visible in fig. 7S, the ends of the frame side walls may include one or more protrusions, such as fingers, that may extend through holes in the lower shelf to form one or more finger connections. A variety of alternative connection structures may be used in addition to the finger connections shown.

Although not shown, the frame side walls or portions thereof may optionally include multiple layers of frame material, for example, to increase general frame strength or mounting strength to the brackets when using the top clamp. Although not shown, the frame side walls may optionally include one or more openings or other features to facilitate mounting to brackets, managing wires, tool access, forming corner joints, and the like.

Although shown as being generally flat, in some embodiments, the frame side walls may be curved inwardly or outwardly or partially curved. Alternatively, the frame side walls may have additional bends or folds to create a lateral "V" shape, a corrugated shape, one or more steps, or the like.

Lower shelf

The lower shelf may be part of the panel receiving structure and may generally be located at an upper portion of the frame side walls and extend at least inwardly from the frame side walls. In some cases, the lower shelf may define an end or height of the frame side wall. In some embodiments, the lower shelf may include only a single layer of frame material (e.g., fig. 7G, 7O, 7P, 7S, 7T, 7CC, 7 EE-7 HH, 7 JJ-7 MM). In some embodiments, the lower shelf may include multiple layers of framing material, which may be referred to as a lower shelf layer. For example, referring to fig. 6A and 6B, lower shelf 605 may include lower shelf layers 605', 605", and 605'". In some embodiments, a portion of the lower shelf may be formed by a bend or series of bends in the frame material at the upper portion of the frame side walls. In some embodiments, a portion of the lower shelf may be formed by a bend or series of bends in the frame material at the upper portion of the support wall. In some embodiments, only a portion of the lower shelf may include multiple layers (e.g., fig. 6A, 6B, 7A, 7I, 7L, 7M, 7Q, 7U-7Y, 7BB, 7DD, 7NN, 7 OO). In some embodiments, substantially all of the lower shelves may include multiple layers (e.g., fig. 7B-7F, 7J, 7K, 7N, 7R, 7Z, 7AA, 7 II). In some cases, the panels of the frame panel structure may rest on at least a portion of the lower shelf. The upper surface of the lower shelf that is adjacent to the panel may alternatively be referred to as the panel-side portion of the lower shelf.

In some embodiments, in addition to extending inwardly, a portion of the lower shelf may also extend outwardly from the frame side wall (e.g., fig. 7L, 7M, 7DD, 7 OO).

In some embodiments, the end of the lower shelf opposite the end of the frame side wall (the inner end of the lower shelf) may be generally aligned with or correspond to the top of the support wall (e.g., fig. 6A, 6B, 7A-7C, 7F-7M, 7O-7Y, 7 BB-7 HH, 7 JJ-7 OO). In some embodiments, the end of the lower shelf opposite the end of the frame side wall may extend inwardly, such as toward the center of the panel, beyond the top of the support wall (e.g., fig. 7D, 7E, 7N, 7Z, 7A, 7 II).

Although shown as being generally flat, in some embodiments, the lower shelf may be curved upward or downward or partially curved. Alternatively, the lower shelf may have additional bends or folds to create a "V" shape, an inverted "V" shape, a corrugated shape, or one or more steps.

Support wall

The support wall location may correspond to an interior portion of the frame portion. As discussed, the interior portion may be related to the frame side wall and may not necessarily mean the innermost portion. In some embodiments, the support wall may extend between the bottom flange and the frame side wall, as shown in fig. 7 AA. This is also shown in fig. 14A to 14C later. In some cases, the support wall may intersect the frame side wall at approximately the same location as the lower shelf intersects the frame side wall. In some embodiments, the support wall may extend between the bottom flange and the lower shelf (e.g., fig. 6A, 6B, 7A-7Z, 7 BB-7 OO). In some cases, the top of the support wall may intersect or be generally aligned with the inner end of the lower shelf (e.g., fig. 6A, 6B, 7A-7C, 7F-7M, 7O-7Y, 7 BB-7 HH, 7 JJ-7 OO). In some embodiments, the end of the top of the support wall may intersect the lower shelf somewhere between the end of the lower shelf adjacent the frame side wall and the inner end of the lower shelf (e.g., fig. 7D, 7E, 7N, 7Z, 7 II). As shown later with reference to fig. 14A and 14B, in some embodiments, the frame portion may include support walls, with one portion extending to the frame side walls and another portion extending to the lower shelf.

In some cases, the support wall may optionally include multiple layers of frame material (e.g., fig. 7E, 7 II), for example, to increase frame strength. In some embodiments, the support wall may be formed at least in part by a longitudinal fold at the bottom flange (e.g., fig. 6A, 6B, 7A-7D, 7F-7 HH, 7 JJ-7 OO), a longitudinal fold at the lower shelf (e.g., fig. 6A, 6B, 7A-7I, 7K-7 OO), or both (e.g., fig. 6A, 6B, 7A-7I, 7K-7 HH, 7 JJ-7 OO). In some embodiments, the top of the support wall may generally represent one end of the frame material (e.g., fig. 7J), or alternatively, the bottom of the support wall may include one end of the frame material (not shown). In this case, the end of the support wall may optionally include a structure that may facilitate attachment to the lower shelf when the frame end is at the top of the support wall or may facilitate attachment to the bottom flange when the frame end is at the bottom of the support wall. In some embodiments, the ends of the support wall may include protrusions or fingers that may mate with holes provided in the lower shelf or support wall. For example, fig. 7J illustrates an embodiment in which the top of the support wall includes a finger that engages an aperture in the lower shelf. To further secure the structure, the interface may optionally be crimped. There are many other connection/attachment structures that can be used in place of the fingers and holes and all connection/attachment structures are included in the present application.

In some embodiments, the angle between the support wall and the bottom flange may be about 90 °, such as in the range of about 85 ° to about 95 ° (e.g., fig. 6A, 6B, 7A-7C, 7E-7Y). In some other embodiments, the angle may be outside of this range, for example, in the range of about 45 ° to about 135 ° (e.g., fig. 7D, fig. 7Z, fig. 7 AA). In some embodiments, the angle is approximately a right or acute angle, for example, in the range of about 45 ° to about 90 °. Any angle may be used.

Although not shown, the support wall may optionally include one or more openings or other features to facilitate mounting to a rack, managing wires, tool access, forming corner joints, and the like. Although shown as being generally flat, in some embodiments the support wall may be curved inwardly or outwardly or partially curved. Alternatively, the lower shelf may have additional bends or folds to create a lateral "V" shape, corrugations, or one or more steps.

Closed shape

As mentioned above, the box frame can be applied to any frame portion forming any closed shape in cross section. In some embodiments, the closed shape may include at least a bottom flange, a frame side wall, and a support wall, and have three or more distinct sides in cross-section. A non-limiting example of a box frame with three distinct sides in cross section is shown in fig. 7 AA. Fig. 14A-14C provide a non-limiting example of a box frame with three distinct sides. In some embodiments, the box frame may have four or more distinct sides in cross-section (fig. 6A, 6B, 7A-7Z, 7 BB-7 OO) including a bottom flange, frame side walls, lower shelf, and support walls.

It should be noted that the presence of multi-layer features may be ignored in some cases when characterizing the general nature of box or enclosed shapes. For example, fig. 6E is similar to fig. 6B, but has an approximately closed shape 636 of a general location marker based on features, regardless of the multi-layer structure of the lower shelf. Other features are not labeled for clarity, but are apparent with reference to fig. 6B. Side "a" of enclosed shape 636 may represent a box-like enclosure floor that generally corresponds to the portion of the bottom flange extending between the frame side walls and the support wall. Side "b" of closed shape 636 may represent a box-like enclosure outer wall that generally corresponds to the frame side wall extending between the bottom flange and the lower shelf. Side "c" of enclosed shape 636 may represent a box-like enclosure ceiling that generally corresponds to a lower shelf extending between the frame side walls and the support walls. Side "d" of closed shape 636 may represent a box-like surrounding inner wall that generally corresponds to the support wall extending between the bottom flange and the lower shelf.

Each side of the closed shape may be characterized by an approximate length. Each intersection of two sides of the closed shape may be characterized by an angle. By way of non-limiting example and referring again to fig. 6E, angles +.ab and +.ad may be characterized as approximately right angles or approximately 90 °. Side "d" may be characterized as being generally parallel to side "b", but having a greater length. The angle bc may be characterized as obtuse (greater than 90 °) and the angle cd may be characterized as acute (less than 90 °). A similar analysis can be performed for any of fig. 7A to 7Z. In some cases, the quadrilateral closed shape itself may be further characterized as, for example, a square, rectangle, parallelogram, trapezoid, isosceles trapezoid, diamond, or some other type of quadrilateral shape.

Although an example is not shown in which a significant additional bend is provided in any feature that constitutes a closed shape, such a closed shape may sometimes be characterized as having more than four sides.

Note that in the case of a three-sided enclosure as in fig. 7AA, there may be no corresponding side "c" (with respect to fig. 6E), and the corresponding side "d" of the closed shape may instead represent a box-like enclosure inner wall that generally corresponds to the support wall extending between the bottom flange and the frame side wall.

Bag-shaped wall

The pocket wall may be considered to be part of the panel receiving structure. In an embodiment, the pocket wall extends from the lower shelf and may act as a stop to reduce or prevent lateral sliding or movement of the panels in the frame panel structure. In some cases, the pocket walls may be substantially aligned with the frame side walls (e.g., fig. 6A, 6B, 7A-7K, 7N-7 CC, 7 EE-7 NN). In some embodiments, the pocket walls may be offset inwardly or outwardly relative to the frame side walls (e.g., fig. 7L, 7M, 7DD, 7 OO). In some embodiments, and as shown in this figure, the pocket-like walls may be generally parallel to the frame side walls. In some embodiments, the pocket wall may be disposed at an angle relative to the frame side wall. In some embodiments, the pocket wall may be disposed at an out-of-plane angle of less than about 45 °, or less than about 30 °, or less than about 20 °, or less than about 10 °, relative to the frame side wall.

In some cases, the pouch wall may include multiple layers of frame material (e.g., fig. 7A, 7G, 7H, 7L, 7M, 7P, 7Q, 7T-7Y, 7 AA-7 HH, 7 JJ-7 OO). In some cases, such multiple layers may increase the overall strength of the frame or the mounting strength to the bracket when using the top clamp. In some embodiments, the pouch wall may include a separation element protruding into the pouch region to partially separate the panel from a position flush against the pouch wall (as in fig. 7O). In some cases, the separation element may have a spring-type structure. In some cases, spring-type spacer elements may relax some manufacturing alignment tolerances when building a frame panel structure. Alternatively, the separating element may extend upwardly from the lower shelf. In some cases, the spacer element may allow the optional sealant material to cover a majority of the panel edges to help protect the panel edges from environmental factors and/or provide improved overall strength of the bonding of the panels within the pocket area, as discussed below with respect to the panel receiving structure and the use of an optional adhesive.

Although not shown, the pocket wall may optionally include one or more openings or other features to facilitate mounting to a rack, managing wires, tool access, forming corner joints, etc.

Although shown as being generally flat, in some embodiments, the pouch-like wall may be curved inwardly or outwardly or partially curved. Alternatively, the lower shelf may have additional bends or folds to create a lateral "V" shape, a corrugated shape, or one or more steps.

Top lip

In some embodiments, the top lip may intersect an upper portion of the pouch wall. In some cases, the top lip may be at least partially formed by at least one longitudinal fold at an upper portion of the pouch wall. Although not shown, the top lip may optionally comprise a single layer of framing material. In some embodiments, including but not limited to those formed from a single layer of frame material, the inner end of the top lip may include an upward bend to reduce the risk of the panel being damaged by sharp edges of the frame material.

In some embodiments, the top lip, or at least a portion thereof, may be formed from multiple layers of framing material. In some embodiments, the top lip may include a rounded top lip edge as discussed with respect to fig. 6A and 6B. The rounded top lip edge may be formed by a fold at the inner end of the top lip. This design may have various benefits, for example, it may be more aesthetically pleasing, it may retain the frame edges in pockets, it may aid in edge oxidation, because it may be covered by adhesive, it may cause less accidental damage to the panel by eliminating sharp corners, and it may create natural pockets for optional adhesive. In some cases, the rounded top lip edge may extend completely from the inner end of the top lip back to the pouch wall (e.g., fig. 7L, 7M, 7P, 7T, 7V, 7BB, 7 DD-7 HH, 7JJ, 7KK, 7 MM). In some embodiments, the rounded top lip edge may extend only partially back into the pocket wall where it terminates at one end of the frame material, forming a distinct step within the pocket region (e.g., fig. 6A, 6B, 7A-7K, 7N, 7O, 7Q-7S, 7U, 7W-7 AA, 7CC, 7LL, 7NN, 7 OO). In some cases, such a step may improve the bonding of the panels within the pocket area, as discussed below with respect to the panel receiving structure and the use of an optional adhesive. In some embodiments, the top lip layer formed by the rounded top lip edge may not necessarily extend parallel to the other top lip layer (e.g., in fig. 7Y). In some embodiments, the end of the top lip may be curved upward as shown in fig. 7II, which may also have a set of advantages similar to the rounded top lip edge described above.

In some embodiments, the top lip may include two top lip layers, wherein one of the top lip layers is formed by a fold at the pouch wall and extends only partially toward the inner end of the top lip and terminates at one end of the frame material (e.g., fig. 7A, 7Q, 7U, 7W, 7X, 7Y, 7F, 7LL, 7NN, 7 OO). In some cases, this may form a step within the pocket region (e.g., fig. 7A, 7U, 7W, 7Y, 7LL, 7NN, 7 OO). In some other embodiments, the ends of such top lip layer may be received in a lip pocket formed by a rounded top lip edge (e.g., fig. 7Q, 7X, 7LL, 7NN, 7 OO).

Although shown as being generally flat, in some embodiments the top lip may be curved upward or downward or partially curved. Alternatively, the lower shelf may have additional bends or folds to create a "V" shape, an inverted "V" shape, a corrugated shape, or one or more steps.

Panel receiving structure/pocket area

In some embodiments, in cross-section, the panel receiving structure may include three distinct sides that in cross-section relate to the lower shelf, the pocket wall, and the top lip, which thereby form the panel receiving shape. It should be noted that the presence of multi-layer features may be ignored in some cases when characterizing the general nature of the panel receiving shape. For example, FIG. 6F is similar to FIG. 6B, but the approximate panel receiving shape 646 is marked based on the general location of the panel receiving structural features, regardless of the multi-layer structure of the lower shelf and top lip. Side "e" of panel receiving shape 646 may represent a panel receiving floor generally corresponding to a lower shelf extending between the bag-like wall and an inner end of the lower shelf. Side "f" of panel receiving shape 646 may represent a panel receiving outer wall that generally corresponds to a pocket-like wall extending between a lower shelf and a top lip. Side "g" of panel receiving shape 646 may represent a panel receiving top panel generally corresponding to the top lip. In some cases, the panel receiving shape may generally correspond to a characteristic surface (e.g., the surfaces of the lower shelf, pocket wall, and top lip) adjacent the pocket region 608. These surfaces may be panel sides of various features (e.g., lower shelf, pocket wall, top lip). The panel receiving shape may also be characterized by a pocket-like opening or even mouth (e.g., virtual side "m") extending between the inner end of the lower shelf and the inner end of the upper lip. In some cases, the dimensions of the pocket-like opening are characterized by a distance along the frame height axis at an innermost point where the lower shelf and the top lip overlap (along the frame height axis). When the virtual side "m" is substantially vertical (aligned with the frame height axis), it may correspond substantially to the pocket opening size. If the top lip extends inwardly more or less than the lower shelf, the virtual side "m" may be longer than the pocket opening size.

Each side of the panel receiving shape may be characterized by a substantial length. Each intersection of two sides of the panel receiving shape may be characterized by an angle. By way of non-limiting example and referring again to fig. 6F, angles ++ef and ++fg can be characterized as acute angles (less than 90 °). However, in some cases, either angle may instead be about a right angle (about 90 °) or even an obtuse angle (greater than 90 °). In some embodiments, the angle ++ef (e.g., between the lower shelf and the pouch wall) or the angle ++fg (e.g., between the top lip and the pouch wall) may be independently selected to be in the range of about 50 ° to about 60 °, about 60 ° to about 70 °, about 70 ° to about 80 °, about 80 ° to about 85 °, about 85 ° to about 90 °, about 90 ° to about 95 °, about 95 ° to about 100 °, about 100 ° to about 110 °, about 110 ° to about 120 °, or any combination or any range thereof. In some cases, the sum of angles +.ef and +.fg may be 180 ° or less, for example in the range of about 100 ° to about 120 °, about 120 ° to about 130 °, about 130 ° to about 140 °, about 140 ° to about 150 °, about 150 ° to about 160 °, about 160 ° to about 170 °, about 170 ° to about 175 °, about 175 ° to about 180 °, or any combination or any range of ranges thereof. In some embodiments, side "f" may be characterized as being approximately parallel to side "m" but longer than side "m". That is, in fig. 6F, in some cases, the pocket opening may be less than the pocket wall height (e.g., the interior height of the panel receiving structure adjacent the pocket wall measured along the frame height axis). In some cases, side "f" may be selected such that it is substantially parallel to the panel edge entering the pocket. In some cases, the side "f" may be selected such that it is not parallel to the panel edge, e.g., such that the panel does not rest flush against the pouch wall, which may improve the ability of the sealant to coat the panel edge. In fig. 6F, angles +.em and +.mg can be characterized as obtuse angles (greater than 90 °). However, in some cases, either angle may instead be about a right angle (about 90 °) or even an acute angle (less than 90 °). A similar analysis can be performed for any of fig. 7A to 7Z. Including open side "m", in some cases, the four-sided panel receiving shape itself may also be characterized as, for example, a square, rectangle, parallelogram, trapezoid, isosceles trapezoid, diamond, or some other type of quadrilateral shape that may be fully symmetrical, partially symmetrical, or asymmetrical. In some embodiments, the panel receiving shape may include more than four sides. In some embodiments, the lower shelf, pocket wall, top lip, or any combination thereof may have a substantially uneven surface and may include one or more bends, corrugations or curves without altering the general function of the panel receiving structure.

In some embodiments, the panel receiving structure may include an inner pocket wall layer (proximate the panel) and an outer pocket wall layer forming part of a trapezoidal panel receiving shape. In some cases, for example, as shown in fig. 7A, 7U, 7W, and 7Y, the inner pouch wall layer is contiguous with (perhaps by a fold) an inner top lip layer that extends partially along the top lip feature. This trapezoidal shape may prevent or reduce separation of the inner bag-like wall from the outer bag-like wall during loading. If the top lip layers are bent together as part of forming the panel receiving structure, the outer pocket wall may compress the inner pocket, which may further retain the inner pocket wall to the outer pocket wall. In some cases, referring again to fig. 6F, this compression may occur when ++fg is an acute angle. Additionally, or alternatively, in some cases, the acute angle ++ef between the pouch wall and the lower shelf may similarly help hold the inner pouch wall against the outer pouch wall. It should be noted that when the pouch wall includes an inner pouch wall layer and an outer pouch wall layer, attachment features such as shown in fig. 7G, 7H, and 7T may alternatively or additionally form a trapezoidal plate receiving shape.

In some embodiments, the frame or frame portion includes one or more features that help support the panel receiving structure, for example, to help reduce or prevent sagging or sliding of the lower shelf or pouch wall under pressure. In some cases, such a panel receiving support feature may be considered part of a lower shelf and include a fold structure in an upper portion of the frame side walls and/or in an upper portion of the support wall upon which one or more other lower shelf layers rest. In some embodiments, the panel-receiving support feature may extend from the frame side wall at an angle that may be substantially parallel to any other lower shelf layers that do not form part of the panel-receiving support feature. Most of the figures shown herein have one or the other panel receiving support features. In some cases, the panel receiving support feature may include a finger connection as discussed herein. In some cases, the panel receiving support feature may include the attachment feature in question. For example, the frames shown in fig. 7G, 7H, 7P, 7T, 7A, 7CC, 7EE, 7GG, 7HH, and 7 JJ-7 MM may include attachment features between the inner and outer pouch wall layers. In some cases, the sealant applied within the pocket area may also serve as a panel-receiving support feature by bonding to the pocket wall, top lip, and/or lower shelf (e.g., as shown in fig. 7O).

Sealant and panel accommodating structure

In some embodiments, the sealant may be optionally applied within the panel receiving structure or to an edge region of the panel, or both, such that when the frame panel structure is assembled, the sealant may be dispersed within at least a portion of the panel receiving structure or pocket region. The sealant may have one or more functions. In some cases, the sealant acts as a coating to protect the surface and edge areas of the panel to reduce the chance of degradation by environmental factors such as the ingress of water or contaminants. Typically, the panel is a multi-layer structure that may have interfaces that are easily exposed at the edges of the panel.

In some cases, the sealant may be formed of a material that is more compressible than the frame material. For example, the sealant may include a polymeric material. This may reduce the transmission of external physical forces acting on the frame to the panel.

The sealant may be an adhesive sealant that adheres to both the panel and the frame material of the panel receiving structure. This may add additional strength to the frame and the ability to resist external forces. The use of a sealant may allow more design freedom of the frame or increase manufacturing tolerances of the frame assembly by not relying solely on the frame structure to provide the desired properties.

Fig. 9A is a cross-sectional view of a non-limiting example of a frame panel structure, enlarged to show a panel receiving structure portion of a frame portion, according to some embodiments. The frame panel structure 900 may include a panel 990 disposed in a pocket-like region of the panel receiving structure of the frame portion 901. The panel receiving structure may include a lower shelf (e.g., a lower shelf including lower shelf layers 905', 905", 905 '"), a pouch wall 906, and a top lip forming a rounded top lip edge (e.g., a top lip including top lip layer 907' and top lip layer 907 "). Also shown is an edge E1 of the frame material, which may correspond to an end of the top lip layer 907 ". The upper portions of the frame side walls 903 and support walls 932 are also visible in fig. 9A.

At least a portion of the pocket region may include a sealant 955, which may have adhesive properties. In some embodiments, most or all of the pouch region includes a sealant 955. In some cases, it may be desirable to provide at least some sealant 955 between the edge of the panel 990 and the pouch wall 906. In some cases, it may be desirable to prevent the sealant from extending substantially beyond the inner end of the top lip so that the sealant does not interfere with the function of the panel, for example, if the panel is a solar panel. In some cases, during assembly, if there is an excess of sealant, it may be desirable to allow or direct it to spill over onto the underside of the panel or support wall. Pushing the panel upward toward the top of the pocket during assembly may also help reduce or prevent sealant from flowing out at the top of the panel. Advantageously, there is no encapsulant flow at the top of the panel for aesthetics and the possibility of encapsulant covering the PV active area, which may reduce the efficiency of the PV panel. In some embodiments, the lower shelf may include one or more apertures to allow excess sealant to escape into the enclosed space of the frame, thereby reducing or preventing the sealant from flowing out onto the top of the solar panel.

As can be seen in fig. 9A, the approximate cross-sectional shape of the panel accommodating portion is approximately trapezoidal, with the opening or mouth inside being smaller than the side corresponding to the pocket wall 906. When external forces are applied to the frame panel structure (wind, snow weight, handling, etc.), such forces may sometimes attempt to pull the panel away or out of the panel receiving structure. However, the trapezoidal shape of the sealant may create additional resistance to such pulling due to the advantageous geometry. Furthermore, the step formed by the edge E1 of the framing material at the end of the top lip layer 907 "may create another point of resistance to forces attempting to pull the panel away from the panel receiving structure. That is, edge E1 may act as a sharp wall to make it difficult for the portion of sealant behind the edge (e.g., toward the pouch wall) to be pulled through. Such edges can also effectively resist panel pullout even in the case where the panel accommodating shape is not trapezoidal. In some embodiments, the lower shelf may include a frame edge (e.g., fig. 7K and 7N) that may form a step that may also act as a sharp wall against the panel pulling out.

In some embodiments, the sealant need not fill all of the available space in the pocket area. Fig. 9B is similar to fig. 9A except that the encapsulant 955B does not completely fill the pocket area, but leaves a partial space in the gap behind edge E1. In some embodiments, the gap behind edge E1 may serve as a region for sealant to overflow. Although not shown, the top lip layer 907' may include one or more holes on the area between the edge E1 and the pocket wall, which holes may be filled with sealant, which may provide improved bonding of the panel within the panel receiving structure, or even allow additional sealant overflow paths. If the encapsulant is transparent to visible light, such holes may, in some cases, further allow additional light to reach the solar panel and increase its efficiency.

Fig. 9C-9E are cross-sectional views of some more non-limiting examples of frame panel structures for further illustrating the use of sealant within the panel receiving structure, in accordance with some embodiments. These figures are similar to fig. 9A except that a different frame portion structure is used. Although not all of the frame features are labeled, their identification is apparent from the remainder of this disclosure. Each example may have one or more of the same characteristics or benefits as described above, even if not always mentioned.

In fig. 9C, the frame portion may be similar to the frame portion shown in fig. 7A. The gap 962 between the two edges of the frame material may form a space for sealant 955C to escape and (if filled) the frame edges may further serve as a resistance step or feature against the panel 990 pulling out.

In fig. 9D, the frame portion may be similar to the frame portion shown in fig. 7Y. Instead of being parallel to the two top lip layers in fig. 9A, top lip layer 907D "may be disposed at an angle relative to top lip layer 907D' such that a gap 962 is formed between the two layers of frame material. In some cases, the lower top lip layer 907D "may be disposed at an angle substantially parallel to the panel surface, which helps guide the panel into the panel receiving structure. The encapsulant 955D disposed in the gap and/or behind the edges of the frame material may act as a resistance step or feature against the pull-out of the panel 990.

In fig. 9E, the frame portion may be similar to the frame portion shown in fig. 7O, fig. 7O showing a non-limiting example of a separation element. In some cases, the separation element 964 may ensure that the panel edge is not flush with the pouch wall. As shown in fig. 9E, this may help to allow sufficient sealant 955E to be provided between the edge of panel 990 and the pouch wall.

In some embodiments, the lower shelf may include a structure that increases the contact surface area between the sealant and the lower shelf. Fig. 10A and 10B are perspective views of some non-limiting examples of frame portions with structured lower shelves according to some embodiments. Although not all of the frame features are labeled, their identification is apparent from the remainder of this disclosure. In fig. 10A, the lower shelf may include a plurality of lower shelf layers 1005A ', 1005A ", and 1005A'". The upper layer of the lower shelf (e.g., panel-side lower shelf layer 1005A') may include an edge E1A of frame material that has been cut to form a patterned edge such that the frame edge is no longer linear. The patterned edge E1A in fig. 10A is shown as a scalloped or wavy edge, but many other shapes may be used so that the patterned edge may appear to include serrations, fingers, steps, etc., which may have a uniform pattern or a non-uniform pattern. In some embodiments, the length of the panel side layer of the lower shelf between the inner end and the patterned edge varies by at least about 2% on average over the frame portion, alternatively by at least about 5%, about 10%, about 20%, or about 30% on average, etc. In fig. 10B, the lower shelf may include a plurality of lower shelf layers 1005B' and 1005B ". The upper layer of the lower shelf (panel-side lower shelf layer 1005B') may include one or more holes 1025. The holes in fig. 10B are shown as uniform lines, but the holes may be in some other uniform or non-uniform pattern. In some embodiments, the apertures may occupy at least about 2%, or at least about 5%, about 10%, about 20%, about 30%, about 40%, or about 50%, etc., of the area relative to the panel-side lower shelf of the frame portion.

In some cases, as shown, for example, in fig. 10A and 10B, the structured lower shelf may expose additional surface area of one or more lower shelf layers in addition to the panel-side lower shelf layer. This may increase the total area of the bond between the sealant and the lower shelf. In some cases, the structured lower shelf (e.g., with holes or patterned edges or both) may act as a resistance step or feature against panel pullout. In some cases, a structured lower shelf with a sealant may enable additional bonding between the panel-side lower shelf layer and one or more other lower shelf layers to further strengthen the frame.

For example, as shown in fig. 6A, 6B, 6E, 6F, 7B, 7K, 7O, 9A, 9B, 9E, 10A, and 10B, applying a sealant to the glass and the rest of the pouch wall may also help hold the panel-side lower shelf in place.

In some embodiments, an adhesive may be used to hold the panel-side lower shelf layer to the underlying lower shelf layer, for example, formed by folds at the upper portions of the frame side walls (e.g., as shown in fig. 7I and 7R). In some embodiments, the adhesive may be applied during the bending process (e.g., during the roll forming process). In some embodiments, the adhesive material used between the layers of frame material may be the same as the sealant, or alternatively, it may be different.

In some embodiments, the pouch wall may include a plurality of pouch wall layers, for example, as shown in fig. 7A, 7G, 7H, 7L, 7M, 7P, 7Q, 7T, 7U-7Y, 7 AA-7 HH, and 7 JJ-7 OO. Although not shown, the pouch-like wall layer may have a similar structure to the structured lower shelf. For example, the panel-side pocket wall layer may include apertures or patterned edges to form a structured pocket wall in a manner similar to that described in fig. 10A and 10B. In a non-limiting example, fig. 7H shows a panel-side pocket wall layer 706H', which may optionally include holes or patterned edges, which in combination with pocket wall layer 706H "may optionally form a structured pocket wall. The structured bag-like wall may expose additional surface area of one or more bag-like wall layers other than the panel-side lower bag-like wall layer. Consistent with the sealant applied to the panel edges or pocket areas, it may allow for improved bonding of the pocket wall layers together and potentially serve as an attachment feature, which in some cases may be provided in the step of co-forming the panel. This may be particularly useful when the lower shelf does not include folds, steps, or other panel receiving support features resting thereon (e.g., in fig. 7G, 7H, 7P, 7T, 7CC, 7EE, 7GG, 7HH, and 7 JJ-7 MM). In some cases, with such attachment features, the forces applied to the frame side walls and support walls may be more evenly distributed.

Stress modeling

A number of models have been built to simulate the stresses that a frame may experience as a function of the various forces acting thereon. Fig. 11A and 11B illustrate stress models of some non-limiting examples of box frames according to some embodiments. For clarity, various frame features are not labeled, but their identification is apparent from the remainder of this disclosure. Fig. 11A is a cross-sectional view of a frame portion 1101A having a lower shelf comprising a single layer of frame material. Such a frame can be relatively simply manufactured and has many other useful properties and advantages. Fig. 11B is a cross-sectional view of a frame portion 1101B having a lower shelf comprising multiple layers of frame material, e.g., made in part of a fold in the frame material at an upper portion of a frame sidewall. As discussed, the multiple layers may serve as panel receiving support features. Such a frame, while having more folds than that of fig. 11A, can also be relatively simple to manufacture and has many other useful characteristics and advantages.

Fig. 11A and 11B also illustrate a downward force 1140 being applied to the lower shelf. Such forces may be, for example, from the weight of the panel, as well as any snow, wind, top clamps, or other forces that may act on the panel and push down toward the illustrated base. The stresses induced in the frame portion may be analyzed at various points, including: f1 (generally corresponding to the fold or intersection between the lower shelf and the support wall); f2 (typically corresponding to a distance from the lower shelf down to about half of the support wall); f3 is generally (corresponds to a distance from the lower shelf down to about half of the frame side wall); and f-4 (generally corresponding to the fold or intersection between the frame side wall and the bottom flange). The stresses at each point of each frame are summarized in table 1.

TABLE 1

The forces and stresses at each point do not create problems for either frame, depending on the nature of the frame material, the weight of the panel, and other environmental factors desired. However, the structure of frame portion 1101B (with panel receiving support features) may more evenly distribute such stresses at different locations. In some cases, the improved stress distribution may allow a designer to choose a thinner framing material, use heavier panels, or place framing panel structures in more environmentally challenging locations. In some embodiments, the ratio of the stress experienced at the midpoint of the support wall (e.g., point f-2) to the stress experienced at the midpoint of the frame side wall (e.g., point f-3) caused by the weight of the panel may be in the range of about 0.1 to about 10, or alternatively about 0.2 to about 5, about 0.4 to about 3.0, or about 0.5 to about 2. In some embodiments, the stress experienced at the midpoint of the support wall (e.g., point f-2) and the stress experienced at the midpoint of the frame side wall (e.g., point f-3) caused by the weight of the panel may differ from each other by within 10 times, alternatively within 5, 4, 3, or 2 times.

Fig. 12A-12C illustrate stress models of some non-limiting examples of box frames according to some embodiments. For clarity, various frame features are not labeled, but their identification is apparent from the remainder of this disclosure. Fig. 12A is a sectional view of the frame portion 1201A, and fig. 12B is a sectional view of the frame portion 1201B. For fig. 12A and 12B, the box frame includes a multi-layered lower shelf structure. For frame portion 1201B, the lower shelf includes an attachment feature (labeled "×") to bond or otherwise attach the bottommost lower shelf layer to the lower shelf layer above it, which is formed by a fold in the frame material at the upper portion of the frame side walls. The attachment feature may include crimping, adhesive, or any other attachment feature selection discussed in this disclosure. The box frame shown in fig. 12A is similar to that of fig. 12B, but without the attachment features.

Fig. 12C is a general side view of a frame similar to 1201A or 1201B, further including arrows indicating torque 1240 exerted on the panel receiving structure about an axis (labeled "+"). One force arrow is located at the inner end of the upper lip, the other force arrow is located at the top of the pouch wall, and one arrow is located at the base of the pouch wall, all pointing generally clockwise relative to the marking axis. The torque transmitted to the frame produces a positional displacement on the frame portion relative to the home position. The displacement at each point of the frame portion may be analyzed, including: d-1 (generally corresponding to the inner edge of the upper lip); d-2 (generally corresponding to the fold or intersection of the top lip with the pouch wall); d-3 (generally corresponding to the fold or intersection of the lower shelf with the support wall); d-4 (generally corresponding to the inner end of the bottom flange). The displacements experienced at each point of each frame are summarized in table 2.

TABLE 2

While frame portion 1201A may be entirely suitable in many cases, adding attachment features as in frame portion 1201B may impart improved rigidity and substantial resistance to torsional stress on the frame. The attachment features may allow the designer to choose a thinner framing material, use heavier panels, or place framing panel structures in more environmentally challenging locations.

Universal box type frame model

Fig. 13 illustrates a general model useful for understanding some aspects of the present disclosure with respect to stress. Left is a cross-sectional representation (model a-non-box frame) 1800 of the frame side wall portion of the non-box frame portion (i.e., the frame side wall portion that does not include the support wall). For example, it may be similar to the frame side walls shown in fig. 1C or fig. 2C. The frame side walls have a height (h) and a base (b). For illustration purposes, the dimensions of the model a are not shown to precise scale—the base b is generally substantially smaller than the height h. To the right is a cross-sectional representation of the box frame (model B-box frame) 1801, where some of the material from the frame side walls has been redeployed as support walls. The two models have the same cross-sectional area of the frame material and therefore the same amount of frame material. Below each model is a set of equations and term definitions for determining the moment of polar inertia and stress properties. Referring to the equation in fig. 13, it can be seen that changing from a rectangular shape (model a) to a box shape (model B) of similar (scaled) dimensions (while maintaining the same amount of material) results in a 4-fold increase in moment of inertia (4 x). The maximum bending stress in each of these models is inversely proportional to the moment of inertia, so a 4-fold increase in moment of inertia will reduce the bending stress by a factor of 4 (4 x). Similar to bending stress, torsional shear stress is inversely proportional to the moment of polar inertia (J). This means that a 4-fold increase in the moment of polar inertia will reduce the torsional shear stress by a factor of 4 (4 x).

Thus, in some embodiments, a significant improvement in stress performance can be achieved using a box frame relative to a frame without a support wall, without the need for additional frame material and its associated cost and weight.

Additional examples

Fig. 14A is a perspective view of a cut-away portion of a non-limiting example of a frame portion or frame precursor structure that may include a frame support sub-structure, according to some embodiments. The height H and longitudinal L axes are also shown for reference. The frame portion 1401A may include a first longitudinal fold 1402, which may define an intersection of a frame sidewall 1403 and a bottom flange 1404. The frame portion may include a series of folds to form a panel receiving structure that may include a lower shelf 1405, a pocket wall 1406, a top lip 1407, and even a pocket area 1408. In fig. 14A, the frame portion may include another longitudinal fold 1431, which may define an intersection of the support wall 1432 and the bottom flange 1404. The support wall 1432 may extend from the bottom flange to the frame side wall 1403 and may engage with the frame side wall 1403. For engagement, at least a portion of the support wall may be held in place, for example, by friction, geometry, spring force, locking features, attachment features, and the like. The support wall may include an end flange 1435, the end flange 1435 being flush with the side wall 303. In some embodiments, support wall end flange 1435 and side wall 1403 may include features that form locking features 1436. For example, the support wall end flanges may include openings or recesses that receive corresponding plug or raised features already provided in the frame side walls. Alternatively, the end flanges may include raised features that are received by openings or grooves in the frame side walls. Many alternative features may be embedded into the frame to form locking features including, but not limited to, hooks and flexible tabs. In some embodiments, the locking feature may alternatively be or further include some other attachment feature, such as welding, gluing, crimping, riveting, rivets, screws, bolts, and the like. A plurality of locking/attachment features may be used.

In general, the frame side walls, bottom flange, and support wall may form a frame support substructure, and in this case may be characterized as having three sides. That is, the frame portion 1401A may be characterized as a type of three-sided box frame.

The frame support substructure may be varied. Fig. 14B is a perspective view of a cut-away portion of a non-limiting example of a frame portion or frame precursor structure that may include a frame support sub-structure, according to some embodiments. Fig. 14B may be similar to fig. 14A in some respects, but at a different view, showing a portion of the frame portion 1401B below the lower shelf 1405. The lower shelf 1405 may be formed from a series of folds, but in fig. 14B it may include a downwardly directed lower shelf lip 1439, the lower shelf lip 1439 forming a recess in the bottom of the lower shelf. The support wall 1433 may include an end flange having a first end flange portion 1435 and a second end flange portion 1437, the first end flange portion 1435 may be flush with the frame side wall 1403 and the second end flange portion 1437 may fit into a recess of a lower shelf formed by the lower shelf lip 1439. The second end flange portion 1437 may also be considered a layer of the lower shelf. In this way, the support wall may engage both the side wall and the lower shelf (part of the panel receiving structure). The geometry of these features may hold the support wall in place, but may include any of the additional locking/attachment features mentioned previously. The frame side walls, bottom flange and support wall together form a frame support substructure and in this case are characterized by three sides. That is, the frame portion 1401B may be characterized as a type of three-sided box frame.

Fig. 14C is a perspective view of a cut-away portion of a non-limiting example of a frame portion or frame precursor that may include a frame support substructure according to some embodiments. The frame portion 1401C may include a first longitudinal fold 1402, which may define an intersection of a frame sidewall 1403 and a bottom flange 1404. At the upper portion of the frame side walls there may be folds forming a core shelf structure 1441, and the core shelf structure 1441 may include a downward facing lip 1443 that may form a groove. The frame portion may also include another longitudinal fold 1431, which may define an intersection of the support wall 1432 and the bottom flange 1404. The support wall 1432 may extend from the bottom flange to the frame side wall 1403 and may engage with the frame side wall 1403. The support wall may include an end flange 1451 that may engage a recessed portion of the central lower shelf structure 1441. Beyond end flange 1451, there may be a series of bends to form a panel receiving structure that may include lower shelf 1405 (e.g., bent around lip 1443 and over core shelf structure 1441), pocket wall 1406, top lip 1407, and even pocket area 1408. The panel receiving structure of fig. 14C may be based in part on folds in the frame material corresponding to the support wall portions rather than the frame side wall portions. The geometry of these features may hold the support wall in place, but may also include any of the additional locking/attachment features mentioned previously. The frame side walls, bottom flange and support wall together form a frame support substructure and in this case are characterized by three sides. That is, the frame portion 1401C may be characterized as a type of three-sided box frame.

Fig. 15 is a perspective view of a cut-away portion of a non-limiting example of a frame portion or frame precursor structure that may include a frame support sub-structure, according to some embodiments. The height H and longitudinal L axes are also shown for reference. The frame portion 1501 may include a longitudinal fold 1502, which may define an intersection of the frame sidewall 1503 and the bottom flange 1504. The frame or frame precursor structure may include a series of folds to form a panel-receiving structure that may include a multi-layer lower shelf 1505, a pocket wall 1506, a top lip 1507, and even a pocket region 1508. The frame portion may include a reverse flange fold 1539 such that the portion 1504' of the bottom flange may include a double layer of frame material. The other longitudinal fold 1531 may define an intersection of the support wall 1532 and the bottom flange 1504'. The support wall 1532 may extend from the bottom flange to an end of the lower shelf 1505 (part of the panel receiving structure) and may engage with an end of the lower shelf 1505. By "engaged" it may be meant that at least a portion of the support wall is held in place, for example, by friction, geometry, spring force, locking features, attachment features, and the like. The support wall may include an end flange 1535 that may be shaped to receive an end of the lower shelf. Such shaping is sometimes referred to herein as "box-closure folds". In some embodiments, the end flanges may be curled around the ends of the bottom shelf. The top of the support wall end flange 1535 may serve as a lower shelf 1505' (panel side lower shelf). In some embodiments, the top lip 1507 may not extend to the lower shelf 1505. This design may have various benefits, for example, it may create more space between the support wall and the lower shelf for crimping or other engagement mechanisms, or it may allow more sunlight to reach the solar panel by blocking fewer edges of the solar panel. In some embodiments, the top lip 1507 may include a top lip fold 1537 to form a rounded top lip edge. This design may have various benefits, for example, it is more aesthetically pleasing, it may cause less accidental damage to the panel by eliminating sharp corners, and it may create a natural pocket for the optional adhesive. In some cases, the cross-sectional view of fig. 15 may be similar to the cross-sectional view shown in fig. 7N.

While a structure similar to that of fig. 15 may already include locking features due to geometry and/or crimping, alternative or additional locking/attachment features may be used. In general, the frame side walls, bottom flange, support wall, and lower shelf may form a frame support substructure, and in this case may be characterized as having four sides. That is, the frame portion 1501 can be characterized as a type of four-sided box frame.

As discussed above, many of the frame structures discussed herein may be manufactured using a combination of cutting, stamping, and/or folding. In some embodiments, roll forming is used to perform some or all of the folding. Many sequences may potentially be used, but non-limiting examples of process flows for forming structures that may be similar to fig. 15 according to some embodiments are shown in fig. 16A-16K. Fig. 16A-16K are a series of cross-sectional views (except fig. 16J) along the width of the strip of framing material.

Fig. 16A shows a non-limiting example of step 1 1700, which may be a step of cutting and/or punching the frame material. Step 1 may include forming some or all of the desired cuts and punches in the frame material that may achieve the frame features, such as notches and the like. The cutaway portion shown in fig. 16A does not correspond to a notched area or other area with a cut or punched hole, so it may simply appear to be a flat sheet of frame material 1540.

Fig. 16B shows a non-limiting example of step 2 1701, which may be a top lip folding step. Step 2 may include forming a top lip fold 1537. Fig. 16C shows a non-limiting example of step 3 1702, which may be a box-type closed folding step. Step 3 may include forming a box closure fold 1535. Fig. 16D to 16F show non-limiting examples of step 4, step 5 and step 6, respectively. Step 4 1703 may be a lower shelf fold #1. Step 5 1704 may be a lower shelf fold #2. Step 6 1705 may be a lower shelf fold #3. Steps 4 to 6 may include forming the lower shelf fold #1, #2, and #3, respectively, to form the lower shelf 1505. Fig. 16G shows a non-limiting example of step 7 1706 and step 8 1707, which may be box folds #1 and #2. Steps 7 and 8 may include forming box folds #1 and #2, which may include folds corresponding to fold 1531 and folds corresponding to a beginning portion of bottom flange double fold 1539, where fold 1531 may define an intersection of a portion that may become support wall 1532 and a portion that may become bottom flange 1504'. Fig. 16H shows a non-limiting example of step 9 1708, which may be box fold #3. Step 9 may include forming box fold #3, which may include a fold corresponding to fold 1502, which fold 1502 may define an intersection of frame sidewall 1503 and bottom flange 1504. Fig. 16I shows a non-limiting example of step 10 1709, which may be box fold #4. Step 10 may include forming a box fold #4 where a double flange portion may be formed and a box closure fold may mate with an end of the lower shelf. Fig. 16J is a perspective view showing step 11, a non-limiting example of step 11 1710, which may be a step of crimping the box-closure fold to the lower shelf. Step 11 may be a step in which the box-type closure fold may be curled using a crimping roller 1660 to tightly secure the support wall to the end of the lower shelf. In some embodiments, the crimping rollers may include teeth. Fig. 16K shows a non-limiting example of step 12 1711, which may be a bag folding step. Step 12 may include forming a pocket fold defining a top lip 1507 and a pocket wall 1506. In some embodiments, the bag fold may be performed prior to installation to the panel. In some embodiments, the bag-like fold may be performed during panel installation, for example, with the panel positioned in place with an optional adhesive. In embodiments, any number of steps may be used, and may be in any order.

During or after this sequence there may be additional steps not shown, for example applying straightening rolls, additional cutting or punching, polishing etc. Those skilled in the art will appreciate that there are many variations of the order and that fig. 16A-16K represent just one non-limiting example. In some embodiments, some folding steps may be performed in parallel rather than sequentially.

Although their application in the manufacture of frames for solar panels is described herein, the methods, apparatus and devices of the present application may be used to manufacture many other products in many other fields. In some cases, such other products may be those formed at least in part from generally planar starting materials, including but not limited to sheet metal (again coated or uncoated).

It should be noted that the various parts and frame features (including, but not limited to, frame side walls and bottom flanges) are generally represented in their respective figures as being straight or planar, but in some embodiments, one or more of these features (or other features shown as being straight or planar) may alternatively be non-straight or non-planar. For example, one or more of these features may include one or more curves or additional bends, and still effectively perform its intended function.

It is also noted that in any of the figures herein, rounded corners may be substituted for folds that may be represented as having sharp corners. In some embodiments, the corners formed by the folds may be characterized by a bend radius.

In some embodiments, in areas where a portion of the frame material may be in contact with another material (including but not limited to another portion of the frame material, bolts, washers, support structures, etc.), these areas may optionally include a corrosion resistant coating or additional corrosion resistant coating treatments, including but not limited to those already discussed.

In some embodiments, in areas where multiple layers of framing material are formed, these areas may optionally include bonding or attachment features that hold the layers together. Some non-limiting examples of attachment features may include crimping, riveting, interlocking features between layers, double-sided tape, adhesives, welding, brazing, solder, and the like. In some embodiments, the corrosion resistant coating may also have adhesive properties and act as an attachment feature.

Further embodiments herein include the embodiments listed below. In these enumerated embodiments, the terms "include" (and variants thereof, "include," "include") include "in addition to" comprising, "" including, "and/or" consisting of …, "" consisting of …, "" …, "" consisting of, "and/or" consisting essentially of … (consisting essentially of) ("consisting essentially of … (consists essentially of)", "consisting essentially of … (consist essentially of)"), the normal meaning thereof is also included.

Detailed description of the illustrated embodiments

Listed embodiment 1: a frame for at least partially enclosing or supporting a panel, the frame comprising at least a first frame portion, the first frame portion comprising:

a bottom flange disposed at a base of the frame portion;

a frame side wall disposed at an outer portion of the frame portion, the frame side wall characterized by a height extending from the bottom flange;

a panel receiving structure at an upper portion of the frame side wall, the panel receiving structure including a lower shelf extending from the frame side wall; and

a support wall disposed at an inner portion of the frame portion, the support wall extending between the bottom flange and the frame side wall, between the bottom flange and the lower shelf, or between the bottom flange and the frame side wall and between the bottom flange and the lower shelf,

wherein the bottom flange, the frame side walls, the panel receiving structure and the support wall are at least partially formed by folds provided in a single sheet of frame material.

Enumerated embodiment 2: the frame of enumerated embodiment 1 or any other enumerated embodiment, further comprising a longitudinal fold defining an intersection of the frame sidewall and the bottom flange.

Enumerated embodiment 3: the frame of enumerated embodiments 1 or 2 or any other enumerated embodiment, wherein at least a portion of the bottom flange, the frame side wall, the lower shelf or the support wall, or any combination thereof, comprises at least two layers of frame material.

Enumerated embodiment 4: the frame of any one of the enumerated embodiments 1-3 or any other enumerated embodiment, wherein the panel receiving structure further comprises a pocket wall extending from the lower shelf.

Listed embodiment 5: the frame of enumerated embodiment 4 or any other enumerated embodiment, wherein at least a portion of the pouch wall comprises at least two layers of frame material.

Enumerated embodiment 6: the frame of enumerated embodiments 4 or 5 or any other enumerated embodiment, wherein the panel-receiving structure further comprises a top lip intersecting an upper portion of the pocket wall, thereby forming a pocket region for receiving the panel, the pocket region being defined by the lower shelf, the pocket wall, and the top lip.

Enumerated embodiment 7: the frame of enumerated embodiment 6 or any other enumerated embodiment, wherein at least a portion of the top lip comprises at least two layers of frame material.

Listed embodiment 8: the frame of enumerated embodiments 6 or 7 or any other enumerated embodiments, wherein an angle formed by the lower shelf and the pocket wall is in a range of about 50 ° to about 90 °.

Enumerated embodiment 9: the frame of any one of the enumerated embodiments 6-8 or any other enumerated embodiment, wherein an angle formed by the top lip and the pouch wall is in a range of about 50 ° to about 90 °.

Enumerated embodiment 10: the frame of enumerated embodiment 9 or any other enumerated embodiment, wherein the pocket wall comprises a multi-layer frame material comprising a panel-side pocket wall layer connected to a lower shelf layer by a fold, and wherein an angle formed by the top lip and the pocket wall is less than about 90 °.

Enumerated embodiment 11: the frame of enumerated embodiment 10 or any other enumerated embodiment, wherein the top lip comprises a multi-layer frame material comprising a panel-side top lip layer connected to the panel-side pocket wall by a fold.

Enumerated embodiment 12: the frame of either of the enumerated embodiments 10 or 11 or any other enumerated embodiments, wherein the panel-side pocket walls are locked in place by geometric or compressive forces or both.

Listed embodiment 13: the frame of any one of enumerated embodiments 6-9 or any other enumerated embodiment, wherein a pocket opening between an inner end of the lower shelf and an inner end of the top lip is less than a pocket wall height along a frame height axis.

Enumerated embodiment 14: the frame of any one of the enumerated embodiments 6-13 or any other enumerated embodiment, wherein at least one edge of frame material is disposed within the panel receiving structure.

Enumerated embodiment 15: the frame of enumerated embodiment 14 or any other enumerated embodiment, wherein a predetermined step or gap is formed at an edge of the frame material within the panel receiving structure, the predetermined step or gap forming a region for sealant overflow.

Enumerated embodiment 16: the frame of enumerated embodiments 14 or 15 or any other enumerated embodiments, wherein a predetermined step or gap is formed at an edge of the frame material within the panel receiving structure, the predetermined step or gap being combined with an applied sealant to resist pullout of the panel.

Enumerated embodiment 17: the frame of any one of the enumerated embodiments 1-16 or any other enumerated embodiment, wherein the first frame portion further comprises a panel receiving support feature.

Enumerated embodiment 18: the frame of enumerated embodiment 17 or any other enumerated embodiment, wherein the panel receiving support feature comprises a folded structure at an upper portion of the frame side wall or at an upper portion of the support wall.

Enumerated embodiment 19: the frame of enumerated embodiment 18 or any other enumerated embodiment, wherein the panel receiving support feature forms a portion of the lower shelf.

Enumerated embodiment 20: the frame of enumerated embodiment 19 or any other enumerated embodiment, wherein the panel-receiving support feature extends from the frame side wall at an angle that is substantially parallel to any other lower shelf layers that do not form part of the panel-receiving support feature.

Listed embodiment 21: the frame of any one of the enumerated embodiments 1-20 or any other enumerated embodiment, wherein the cross-section of the first frame portion is characterized by an enclosed space comprising at least three sides including the bottom flange, the frame side wall, and the support wall.

Enumerated embodiment 22: the frame of any one of the enumerated embodiments 1-20 or any other enumerated embodiment, wherein the cross-section of the first frame portion is characterized by an enclosed space comprising at least four sides including the bottom flange, the frame side wall, the lower shelf, and the support wall.

Enumerated embodiment 23: the frame of enumerated embodiment 22 or any other enumerated embodiment, wherein a longitudinal fold defines an intersection of the lower shelf and the support wall.

Enumerated embodiment 24: the frame of any one of the enumerated embodiments 1-23, or any other enumerated embodiment, wherein the bottom flange comprises an inward extension, an outward extension, or both.

Enumerated embodiment 25: the frame of any one of the enumerated embodiments 1-24 or any other enumerated embodiment, wherein the bottom flange comprises a roller structure.

Enumerated embodiment 26: the frame of enumerated embodiment 25 or any other enumerated embodiment, wherein the roller structure is designed to engage with attachment features provided on a support structure.

Listed embodiment 27: the frame of any one of the enumerated embodiments 1-26 or any other enumerated embodiment, wherein the bottom flange comprises holes for mounting to a support structure.

Enumerated embodiment 28: the frame of enumerated embodiment 27 or any other enumerated embodiment, wherein the support structure comprises attachment features.

Enumerated embodiment 29: the frame of enumerated embodiment 28 or any other enumerated embodiment, wherein the attachment feature comprises a spring tab.

Enumerated embodiment 30: the frame of any one of the enumerated embodiments 1-29 or any other enumerated embodiment, wherein the lower shelf comprises a panel-side lower shelf layer having a patterned edge.

Enumerated embodiment 31: the frame of any one of the enumerated embodiments 1-30 or any other enumerated embodiment, wherein the lower shelf comprises a panel-side lower shelf layer having one or more apertures.

Enumerated embodiment 32: the frame of any one of the enumerated embodiments 1-31 or any other enumerated embodiment, wherein the panel receptacle comprises a pocket wall having multiple layers of frame material, and wherein the panel-side pocket wall comprises one or more apertures, patterned edges, or both.

Enumerated embodiment 33: the frame of any one of the enumerated embodiments 1-32 or any other enumerated embodiment, wherein the frame portion comprises an attachment feature.

Enumerated embodiment 34: the frame of enumerated embodiment 33 or any other enumerated embodiment, wherein the attachment features comprise grooves, holes, hooks, plugs, tabs, or spring tabs.

Enumerated embodiment 35: the frame of enumerated embodiments 33 or 34 or any other enumerated embodiments, wherein the attachment feature comprises rivets, curls, rivets, welds, adhesives, screws, or bolts.

Enumerated embodiment 36: the frame of any one of the enumerated embodiments 1-35 or any other enumerated embodiment, wherein the frame material comprises coated steel.

Enumerated embodiment 37: the frame of enumerated embodiment 36 or any other enumerated embodiment, wherein the coated steel has a thickness in the range of about 0.7mm to about 1.4 mm.

Enumerated embodiment 38: the frame of any one of the enumerated embodiments 1-37, or any other enumerated embodiment, further comprising a second frame portion having the same or different structure as the first frame portion.

Enumerated embodiment 39: the frame of enumerated embodiment 38 or any other enumerated embodiment, further comprising a third frame portion and a fourth frame portion, each independently selected to be the same or different from the first frame portion.

Enumerated embodiment 40: the frame of any one of the enumerated embodiments 1-39 or any other enumerated embodiment, wherein the frame is formed from a single frame precursor structure.

Enumerated embodiment 41: the frame of any one of the enumerated embodiments 1-39 or any other enumerated embodiment, wherein the frame is formed from a plurality of frame precursor structures.

Enumerated embodiment 42: a frame panel structure comprising a frame according to any one of the enumerated embodiments 1 to 41 and a panel provided in association with the panel receiving structure of the first frame portion.

Enumerated embodiment 43: the framing panel structure of enumerated embodiment 42 or any other enumerated embodiment, wherein the panel is a solar panel.

Enumerated embodiment 44: the frame panel structure of enumerated embodiments 42 or 43 or any other enumerated embodiment, wherein the panel has a weight that applies a first force to a midpoint of a frame side wall of the first frame portion and a second force to a midpoint of a support wall of the first frame section, and wherein a ratio of the second force to the first force is in a range of about 0.2 to about 5.0.

Enumerated embodiment 45: a photovoltaic solar energy system comprising the frame panel structure of the enumerated embodiments 43 or 44 attached to a support structure.

Enumerated embodiment 46: the photovoltaic solar system of enumerated embodiment 45 or any other enumerated embodiment, wherein the frame comprises a bottom flange having mounting holes, and wherein the support structure comprises spring tabs engaging the bottom flange through the mounting holes.

Listed embodiments 47: the photovoltaic solar system of enumerated embodiment 46 or any other enumerated embodiment, wherein the bottom flange further comprises a roller structure engaged by the spring tab.

Enumerated embodiment 48: a method of making a frame precursor structure for use in a frame according to any one of the recited embodiments 1-41 or any other recited embodiment, the method comprising:

providing a framing material to a framing material station;

receiving the framing material at a stamping station, wherein the framing material is cut or stamped into a predetermined pattern to form a patterned framing material; and

The patterned frame material is received at a roll forming station, wherein the patterned frame material is folded or bent into a predetermined shape to form a formed frame material.

Listed embodiment 49: the method of enumerated embodiment 48 or any other enumerated embodiment, wherein the shaped frame material is the frame precursor structure.

Enumerated embodiment 50: the method of enumerated embodiment 48 or any other enumerated embodiment, further comprising:

the shaped frame material is received at a post-shaping station, wherein the shaped frame material is acted upon by one or more post-shaping processes to form the frame precursor structure.

Enumerated embodiment 51: the method of enumerated embodiment 50 or any other enumerated embodiment, wherein the one or more post-forming processes comprise:

cutting the frame precursor structure to a predetermined length;

passing the formed frame material over a straightening roll; or (b)

Polishing or deburring the formed frame material.

Enumerated embodiment 52: the method of any one of the enumerated embodiments 48-51 or any other enumerated embodiment, wherein the framing material is provided in roll form.

From the foregoing it will be readily appreciated that the basic concepts of the various embodiments of the application may be implemented in numerous ways. It relates to frames, frame precursor structures, frame portions, frame panel structures and/or mounting techniques and apparatus for implementing appropriate frames, frame precursor structures, frame portions, frame panel structures and/or mounting techniques. In the present application, the frame, frame precursor structure, frame portion, frame panel structure, and/or mounting techniques are disclosed as part of the results shown, as achieved by the various devices described, and as inherent steps of use. They are simply natural results of using the devices contemplated and described. Furthermore, while some devices are disclosed, it should be understood that these devices not only implement certain methods, but may be varied in many ways. Importantly, with respect to all of the foregoing, all of these aspects should be understood to be included in the present disclosure.

The discussion included in this application is intended to serve as a basic description. The reader should appreciate that a particular discussion may not explicitly describe all embodiments possible; many alternatives are implicit. It may also not fully explain the generic nature of various embodiments of the application and may not explicitly show how each feature or element can actually be representative of a broader function or of a great variety of alternative or equivalent elements. As one example, terms of degree, approximation, and/or relative terms may be used. These may include terms such as the following: basically, about, only, etc. These words and types of words are to be understood in a dictionary sense to include a large or substantial number, quantity, size, etc. of terms, as well as to include to a large extent but not entirely the specified terms. Furthermore, for the purposes of the present application, terms of degree, approximation, and/or relative terms, if used or when used, should be understood to also include more precise and even quantitative values, which comprise various levels of precision and the likelihood of a requirement that addresses many quantitative choices and alternatives. For example, within the scope of end use, the presence or absence of a substance or condition in a particular input, output, or particular stage may be specified as substantially only x or substantially no x, a value specified as about x, or such other similar language. Using percentage values as an example, these types of terms should be understood to encompass the option of percentage values, including 99.5%, 99%, 97%, 95%, 92% or even 90% of the specified value or relative condition; accordingly, for values at the other end of the spectrum (e.g., substantially free of x), these should be understood to include the option of a percentage value that includes no more than 0.5%, 1%, 3%, 5%, 8%, or even 10% of the specified value or relative condition, all of which may be specified as volume or weight. In this context, it will be understood by those of ordinary skill in the art that these should be disclosed and included in evaluating a group or substance in absolute terms or as compared to the value of a second group or substance. Moreover, such content is also implicitly included in the present disclosure and should be (and is considered to be) understood by one of ordinary skill in the art. When the application is described in device-oriented terminology, each element of the device implicitly performs a function. Apparatus claims may be included not only in the described apparatus but also in method or process claims to address the functions of the application and the functions performed by each element. Neither the description nor the terminology is intended to limit the scope of the claims to be included in any subsequent patent application. As used herein and in the appended claims, the singular forms "a," "an," and "the" include plural referents unless the context clearly dictates otherwise. Thus, for example, reference to "a method" includes a plurality of such methods, and reference to "an anode" includes reference to one or more anodes and equivalents thereof known to those skilled in the art, and so forth. Terms such as "overlying," "over …," and the like, may be direct contact, indirect contact, over …, over …, overlying, and the like.

It should also be understood that various changes may be made without departing from the spirit of the various embodiments of the application. Such variations are also implicitly included in the description. They still fall within the scope of the various embodiments of the application. A broad disclosure including the explicit embodiments shown, the various implicit alternative embodiments, and the broad methods or processes, etc. is encompassed by the present disclosure and can be relied upon when drafting claims for any subsequent patent application. It should be appreciated that such language changes and broader or more detailed claims may be made at a later date (e.g., by any required deadlines) or in the event that the applicant subsequently seeks a patent application based on the application. With this understanding, the reader should appreciate that the disclosure should be understood to support any subsequently filed patent application that may seek to examine the basis of the claims considered within the scope of the applicant's rights and that may be designed to produce a patent that covers aspects of embodiments of the application both independently and as an overall system.

Furthermore, each of the individual elements of the embodiments of the application and claims may also be implemented in a variety of ways. Additionally, when used or implied, an element should be understood to include single as well as multiple structures that may or may not be physically connected. The disclosure should be understood to include each such variation, whether it be a variation of an embodiment of any apparatus embodiment, method or process embodiment, or even merely a variation of any element of these embodiments. In particular, it is to be understood that, since the present disclosure relates to elements of various embodiments of the application, the words of each element may be expressed in terms of equivalent apparatus or method even though only the function or result is the same. Such equivalent, broader, or even more generic terms should be considered to be encompassed in the description of each element or action. These terms may be substituted as needed to expressly indicate the implicit broad coverage to which embodiments of the application are entitled. As just one example, it should be understood that all actions may be represented as a device for taking the action or an element causing the action. Similarly, each physical element disclosed should be understood to encompass a disclosure of the actions that the physical element facilitates. With respect to this last aspect, as just one example, the disclosure of "fold" should be understood to include disclosure of "fold" action (whether explicitly discussed or not), and conversely, the disclosure of "fold" action being valid should be understood to include disclosure of "fold" and even disclosure of "apparatus for folding. Such variations and alternative terms are to be understood to be expressly included in the description. Moreover, each such device (whether explicitly described or not) should be understood to include all elements that can perform a given function, and all descriptions of elements that perform that function should be understood as non-limiting examples of devices for performing that function. As other non-limiting examples, it should be understood that a required element may also be expressed as any one of the following: a component configured or configured and arranged to achieve a particular result, use, purpose, condition, function or operation, or a component capable of achieving a particular result, use, purpose, condition, function or operation. All such are to be understood as being within the scope of the present disclosure and written description.

Any patent, publication, or other reference mentioned in this patent application is incorporated herein by reference. Any priority scheme(s) claimed herein are hereby appended and incorporated by reference. Furthermore, for each term used, it should be understood that unless its use in the present application is inconsistent with the broad support of interpretation, common dictionary definitions should be understood to be incorporated for each term and all definitions, optional terms, and synonyms such as those contained in the Landen Buddhist dictionary (Random House Webster's Unabridged Dictionary) (second edition) are incorporated herein by reference. Finally, all references listed in the list of references are hereby incorporated by reference in accordance with the provisional patent application or other information statement filed with the present application, however, for each of the foregoing, such information or statement incorporated by reference herein may be deemed inconsistent with the patent for various embodiments of the present application and such statement is obviously not deemed to be made by the applicant.

References incorporated by reference

Foreign patent document

Foreign file number	Country code	Category code	Publication date	Patent right name
					2020252091	WO	A1	2020-12-17	Origami (Origami) solar energy

Non-patent literature

U.S. provisional patent application No. 63/176,803, filed 4/19/2021. First signature inventor: hubert.
	U.S. provisional patent application No. 63/176,824, filed on 4/19 at 2021. First signature inventor: and (5) barton.
U.S. provisional patent application No. 63/288,556 filed on day 11 and 12 of 2021. First signature inventor: and (5) barton.
	U.S. provisional patent application No. 63/189,591, filed 5/17/2021. First signature inventor: hubert.
U.S. provisional patent application No. 63/213,541, filed on 6/22 of 2021. First signature inventor: hubert.
	U.S. provisional patent application No. 63/224,271, filed on 7.21, 2021. First signature inventor: and (5) barton.
U.S. provisional patent application No. 63/272,086, filed on 10/26 of 2021. First signature inventor: and (5) barton.

Applicant(s) should therefore be understood to support and claim embodiments including at least the following: i) Each of the frames, frame precursor structures, frame portions, frame panel structures, and/or mounting techniques as disclosed and described herein; ii) the related methods disclosed and described; iii) Similar, equivalent, or even implicit variations of each of these devices and methods; iv) those alternative designs that implement each of the functions disclosed and described; v) those alternative designs and methods that implement each of the functions shown implicitly implement the disclosed and described functions; vi) each feature, component, and step shown as separate and independent applications; vii) applications enhanced by the various systems or components disclosed; viii) the resulting products resulting from such processes, methods, systems or components; ix) each of the systems, methods, and elements shown or described as presently mentioned as being applicable to any particular field or device; x) a method and apparatus substantially as hereinbefore described and with reference to any of the accompanying examples; xi) apparatus for performing the methods described herein, including apparatus for performing the steps; xii) various combinations and permutations of each of the disclosed elements; xiii) each potential dependent claim or concept as a dependency on each of the proposed independent claims or concepts; and xiv) all applications described herein.

Moreover, with respect to computer aspects and each aspect adapted for programming or other electronic automation, it should be appreciated that these and all other aspects of the various embodiments of the application, whether characterized as a device, capability, element, or otherwise, as all can be implemented in software, hardware, or even firmware structures established for a general purpose computer, programmed chip or chipset, ASIC, special purpose controller, subroutine, or other known programmable or circuit-specific structure. It should be understood that all of these aspects are defined at least by the following structures, including those well recognized by those of ordinary skill in the art: hardware circuitry, firmware, programmed special purpose components, and even a general-purpose computer programmed to implement the identified aspects. For such an item as implemented by programmable features, the applicant(s) should be understood to support the claims and make at least the following statements of the application: xv) a process performed by or on a computer, machine, or computing machine throughout the above discussion; xvi) programmable devices described throughout the above discussion; xvii) a computer readable memory encoded with data to direct a computer of a device or element comprising the functionality as described throughout the above discussion; xviii) a computer, machine or computing machine configured as disclosed and described herein; xix) subroutines and/or procedures, alone or in combination, as disclosed and described herein; xx) a carrier medium carrying computer readable code for controlling a computer to individually perform each of the individual and combined methods described herein or in any claim; xxi) computer programs that individually perform each of the individual and combined methods disclosed; xxii) a computer program containing all and each combination of devices for performing each and every single and combined step disclosed; xxiii) a storage medium storing each of the disclosed computer programs; xxiv) a signal carrying the disclosed computer program; xxv) a processor executing instructions for performing the detailed steps and activities; xxvi) circuit configurations (including configurations of transistors, gates, etc.) for ordering and/or causing detailed actions; xxvii) a computer-readable medium storing instructions for performing the steps and causing detailed actions; xxviii) the related methods disclosed and described; xxix) similar, equivalent, or even implicit variations of each of these systems and methods; xxx) those alternative designs that implement each of the functions disclosed and described; xxxi) those alternative designs and methods that implement each of the functions disclosed and described, the alternative designs and methods being shown as implicit to implement the functions disclosed and described; xxxii) each feature, component, and step shown as separate and independent applications; and xxxiii) various combinations of each of the above and any aspects, all without limitation to still other aspects. Furthermore, the applicant should understand to support the claims and make claim recitations that may include claims directed to any recited embodiment and any permutation or combination thereof.

For the purposes of examining claims that are now or later presented, it is to be understood that for practical reasons, the applicant may present only the initial claims, or perhaps only the initial claims and the initial dependent claims, at any time in order to avoid greatly expanding the examination burden. The review of the opinion and any third person interested in the potential scope of this or a subsequent application should understand that in such a case, where the benefit of the case is claimed, the broader claims may be presented at a later date, or in any continuation, regardless of any preliminary modification, other modification, claim language or demonstration presented, and therefore, no attempt is made to forego or forego any potential subject matter during the pendency of any event. It should be appreciated that any related art that may be considered at any prior time may need to be revisited if or when a broader claim is presented, as any amendment, claim language, or dispute presented in this or any subsequent application is likely to be deemed to avoid such prior art, the reason being eliminated by the claims presented below, and the like. It should be appreciated that no such disclaimer or disclaimer is intended or present, as well as any person interested in existing or later potential coverage, or any possibility to consider whether there is any indication of disclaimer or disclaimer of potential coverage at any time. Furthermore, it should be understood that there is no express intent to be supported by, for example, hakim v.cannon Avent Group, PLC,479F.3d 1313 (Fed. Cir (2007)) or the like in this or any subsequent related content to the extent required by new law, including but not limited to European patent convention No. 123 (2) and U.S. patent Law 35USC 132 or other such law, to allow the addition of any of the various dependencies or other elements presented under one independent claim or concept as a dependency or element under any other independent claim or concept at any time, whether in this or any subsequent application, it should also be understood that applicant has intended to fully and widely obtain coverage available legally.

Furthermore, the transitional phrase "comprising" is used to maintain the "open" claims herein if or when used in accordance with the traditional claim interpretation. Thus, unless the context requires otherwise, it will be understood that the term "comprise" or variations such as "comprises" or "comprising" are intended to imply the inclusion of a stated element or step or combination of elements or steps but not the exclusion of any other element or step or combination of elements or steps. These terms should be construed in their broadest form so as to provide the applicant with the broadest coverage that is legally permitted. The use of the phrase "or any other claim" is used to provide support for any claim to be dependent on any other claim, such as another dependent claim, another independent claim, a previously listed claim, a subsequently listed claim, etc. As a clear example, if the claim is "dependent on claim 20 or any other claim" or the like, it can be re-drafted as dependent on claim 1, claim 15 or even claim 25 (if present) if desired, and still fall within the present disclosure. It should be understood that this phrase also provides support for any combination of elements in the claims, and even includes any desired suitable pre-form basis for certain claim combinations, e.g. in combination with a method, apparatus, process or the like.

Finally, any claim set forth at any time is incorporated herein by reference as part of this specification for various embodiments of the application, and applicant expressly reserves all rights to use all or part of the claims as additional description to support any or all of the claims or any element or component thereof, and applicant further expressly reserves the right to move any or all of the claims or any element or component thereof from the specification into the claim, or vice versa, if desired, to define the application or any subsequent continuation, division or partial continuation of the application for protection, or to obtain any benefit in accordance with or following any national patent laws, rules, or ordinances, or treatises, and such contents incorporated by reference should be in full duration of the pending duration of the application, including any subsequent continuation, division, or partial continuation of the application thereof, or any reissue or delay thereof.

Claims

1. A frame for at least partially enclosing or supporting a solar panel, the frame comprising at least a first frame portion, the first frame portion comprising:

A bottom flange disposed at a base of the frame portion;

a support wall disposed at an interior portion of the frame portion, the support wall extending between the bottom flange and the frame side wall, between the bottom flange and the lower shelf, or between the bottom flange and the frame side wall and between the bottom flange and the lower shelf,

2. The frame of claim 1, further comprising a longitudinal fold defining an intersection of the frame sidewall and the bottom flange.

3. The frame of claim 1, wherein at least a portion of the bottom flange, the frame side wall, the lower shelf, or the support wall, or any combination thereof, comprises at least two layers of frame material.

4. The frame of claim 1, wherein the panel receiving structure further comprises a pocket wall extending from the lower shelf.

5. The frame of claim 4, wherein at least a portion of the pocket wall comprises at least two layers of frame material.

6. The frame of claim 4, wherein the panel receiving structure further comprises a top lip intersecting an upper portion of the pocket wall, thereby forming a pocket region for receiving the panel, the pocket region defined by the lower shelf, the pocket wall, and the top lip.

7. The frame of claim 6, wherein at least a portion of the top lip comprises at least two layers of frame material.

8. The frame of claim 6, wherein an angle formed by the lower shelf and the pocket wall is in a range of about 50 ° to about 90 °.

9. The frame of claim 6, wherein an angle formed by the top lip and the pocket wall is in a range of about 50 ° to about 90 °.

10. The frame of claim 9, wherein the pocket wall comprises a multi-layer frame material comprising a panel-side pocket wall layer connected to a lower shelf layer by a fold, and wherein an angle formed by the top lip and the pocket wall is less than about 90 °.

11. The frame of claim 10, wherein the top lip comprises a multi-layer frame material comprising a panel-side top lip layer connected to the panel-side pocket wall by a fold.

12. The frame of claim 10, wherein the panel-side pocket walls are locked in place by geometry, compressive force, or both.

13. The frame of claim 6, wherein a pocket opening between an inner end of the lower shelf and an inner end of the top lip is less than a pocket wall height along a frame height axis.

14. The frame of claim 6, wherein at least one edge of frame material is disposed within the panel receiving structure.

15. A frame according to claim 14, wherein a predetermined step or gap is formed at the edge of the frame material within the panel receiving structure, the predetermined step or gap forming a region for sealant overflow.

16. A frame as claimed in claim 14 wherein the edges of the frame material within the panel receiving structure form a predetermined step or gap which, in combination with the applied sealant, resists pullout of the panel.

17. The frame of claim 1, wherein the first frame portion further comprises a panel receiving support feature.

18. The frame of claim 17, wherein the panel receiving support feature comprises a folded structure at an upper portion of the frame side wall or at an upper portion of the support wall.

19. The frame of claim 18, wherein the panel-receiving support feature forms a portion of the lower shelf.

20. The frame of claim 19, wherein the panel-receiving support feature extends from the frame side wall at an angle substantially parallel to any other lower shelf layers that do not form part of the panel-receiving support feature.

21. The frame of claim 1, wherein the cross-section of the first frame portion is characterized by an enclosed space comprising at least three sides including the bottom flange, the frame side wall, and the support wall.

22. The frame of claim 1, wherein the cross-section of the first frame portion is characterized by an enclosed space comprising at least four sides including the bottom flange, the frame side wall, the lower shelf, and the support wall.

23. The frame of claim 22, wherein a longitudinal fold defines an intersection of the lower shelf and the support wall.

24. The frame of claim 1, wherein the bottom flange comprises an inward extension, an outward extension, or both.

25. The frame of claim 1, wherein the bottom flange comprises a roller structure.

26. The frame of claim 25, wherein the roller structure is designed to engage with attachment features provided on a support structure.

27. The frame of claim 1, wherein the bottom flange includes an aperture for mounting to a support structure.

28. The frame of claim 27, wherein the support structure includes attachment features.

29. The frame of claim 28, wherein the attachment feature comprises a spring tab.

30. The frame of claim 1, wherein the lower shelf comprises a panel-side lower shelf layer having a patterned edge.

31. The frame of claim 1, wherein the lower shelf comprises a panel-side lower shelf layer having one or more apertures.

32. The frame of claim 1, wherein the panel receptacle comprises a pocket wall having multiple layers of frame material, and wherein the panel-side pocket wall comprises one or more apertures, patterned edges, or both.

33. The frame of claim 1, wherein the frame portion includes attachment features.

34. The frame of claim 33, wherein the attachment feature is selected from the group consisting of a groove, a hole, a hook, a plug, a tab, and a spring tab.

35. The frame of claim 33, wherein the attachment feature is selected from the group consisting of crimping, riveting, rivets, welds, adhesives, screws, and bolts.

36. The frame of claim 1, wherein the frame material comprises coated steel.

37. The frame of claim 36, wherein the thickness of the coated steel is in the range of about 0.7mm to about 1.4 mm.

38. The frame of claim 1, further comprising a second frame portion having the same or a different structure than the first frame portion.

39. The frame of claim 38, further comprising a third frame portion and a fourth frame portion, each independently selected to be the same or different from the first frame portion.

40. The frame of claim 1, wherein the frame is formed from a single frame precursor structure.

41. The frame of claim 1, wherein the frame is formed from a plurality of frame precursor structures.

42. A frame panel structure comprising a frame according to claim 1 and a solar panel provided in association with the panel receiving structure of the first frame portion.

43. The frame panel structure of claim 42, wherein the panel has a weight that applies a first stress to a midpoint of the frame side wall of the first frame portion and a second stress to a midpoint of the support wall of the first frame portion, and wherein a ratio of the second stress to the first stress is in a range of about 0.2 to about 5.0.

44. A photovoltaic solar energy system comprising the framing panel structure of claim 42 attached to a support structure.

45. The photovoltaic solar energy system of claim 44 wherein the frame comprises a bottom flange having mounting holes, and wherein the support structure comprises spring tabs that engage the bottom flange through the mounting holes.

46. The photovoltaic solar energy system of claim 45 wherein the bottom flange further comprises a roller structure engaged by the spring tab.

47. A method of manufacturing a frame precursor structure for use in the frame of claim 1, the method comprising:

providing a framing material to a framing material station;

48. The method of claim 47, wherein the shaped frame material comprises the frame precursor structure.

49. The method of claim 47, further comprising:

50. The method of claim 49, wherein the one or more post-forming processes are selected from the group consisting of:

cutting the frame precursor structure to a predetermined length;

passing the formed frame material over a straightening roll; and

polishing or deburring the molded frame material.

51. The method of claim 47, wherein the framing material is provided in roll form.