Methods and systems for connecting solar panel frame components
A frame for at least partially enclosing or supporting a panel is provided. The frame may include at least a first frame section that may include an elongated piece of framework material having a first end and a second end, wherein the first and second ends define a lengthwise dimension. The first frame section may further include lengthwise fold defining an intersection of a frame sidewall with a bottom flange, wherein the frame sidewall is characterized by a height extending from the bottom flange. The first frame section may further include a portion of at least one tab connection assembly where a connected element is attached to the first frame section. The tab connection assembly may include: i) at least one tab feature provided as part of either the first frame section or the connected element, and ii) at least one corresponding hole feature provided as part of the other of the first frame section or the connected element, wherein the hole feature may lockingly receives the at least one tab feature. The connected element may include another frame section, a cross bar, or a racking structure.
1 . A frame for at least partially enclosing or supporting a panel, the frame comprising:
a) a first frame section comprising:
i) an elongated piece of framework material having a first end and a second end, wherein the first and second ends define a lengthwise dimension;
ii) a first lengthwise fold defining an intersection of a frame sidewall with a bottom flange, wherein the frame sidewall is characterized by a height extending from the bottom flange;
iii) a panel containment structure at an upper portion of the frame sidewall;
iv) a reversing flange fold that folds a second layer of framework material backward directly onto the bottom flange to form a double layer of framework material along a first portion of the bottom flange;
v) a support wall; and
vi) a second lengthwise fold defining an intersection of the support wall with the double layer of framework material at the bottom flange;
wherein at least the bottom flange, frame sidewall, panel containment structure, and support wall of the first frame section each collectively form a first frame space that is at least partially enclosed on four sides at the first frame section and at a side of the support wall opposite the double layer of framework material;
b) a second frame section comprising a second frame space that is at least partially enclosed on four sides at the second frame section and at a side of a second frame section support wall opposite a section frame section double layer of framework material; and
c) an insert connector comprising:
i) a first portion that extends at least partially into the first frame space at the side of the support wall opposite the double layer of framework material and lockingly engages the first frame section; and
ii) a second portion that extends at least partially into the second frame space at the side of the support wall opposite the double layer of framework material and lockingly engages the second frame section.
2 . The frame of claim 1 , wherein the insert connector is a corner insert having the first portion provided at an angle relative to the second portion, and wherein the first frame section, second frame section, and corner insert collectively form a corner joint.
3 . The frame of claim 1 , wherein the insert connector engages one or both of the first frame section and the second frame section using a tab connection assembly.
4 . The frame of claim 3 , wherein the tab connection assembly comprises a spring tab, a bent tab, a press-fit tab, or is formed from a tab precursor structure.
5 . The frame of claim 3 , wherein the insert connector comprises a roughened or serrated surface; wherein the tab connection assembly comprises a spring tab on the insert connector; and wherein the spring tab is configured to push the frame sidewalls into the roughened or serrated surface of the insert connector.
6 . The frame of claim 3 , wherein the insert connector comprises a roughened or serrated surface; wherein the tab connection assembly comprises a spring tab on the insert connector; and wherein the spring tab is configured to engage the frame sidewalls of each of the first and second frame sections.
7 . The frame of claim 6 , and further comprising an engagement feature on the first and second frame sections; wherein the engagement features comprise holes or grooves; and wherein the spring tab is configured to engage with the holes or grooves of the first and second frame sections.
8 . The frame of claim 1 , wherein the insert connector comprises a roughened or serrated surface.
9 . The frame of claim 8 , wherein the roughened or serrated surface of the insert connector comprises serrated teeth on the insert connector.
10 . The frame of claim 9 , further comprising an engagement feature on each of the first frame section and the second frame section, wherein the engagement features are configured to lockingly engage with the serrated teeth of the insert connector.
11 . The frame of claim 10 , wherein the engagement features of the first and second frame sections comprise holes or grooves.
12 . The frame of claim 8 , wherein the roughened or serrated surface is located at a top flap edge, a bottom flap edge, or both the top flap edge and bottom flap edge of the insert connector, and wherein the roughened or serrated surface is configured to engage the support walls of the first frame section and the second frame section.
13 . The frame of claim 8 , and further comprising a connector engagement feature of each of the first portion and second portion of the insert connector.
14 . The frame of claim 13 , wherein the connector engagement features comprise a tab connection assembly.
15 . The frame of claim 14 , wherein the tab connection assembly comprises a spring tab, a bent tab, a press-fit tab, or is formed from a tab precursor structure.
16 . The frame of claim 13 , wherein the connector engagement features of the insert connector are configured to push the first and second frame sections into the first and second portions of the insert connector.
17 . The frame of claim 13 , wherein the connector engagement features are configured to push the roughened or serrated surface of the insert connector into the first frame section and the second frame section.
18 . The frame of claim 13 , wherein the connector engagement features of each of the first portion and second portion of the insert connector are configured to push into the frame sidewalls of each of the first and second frame sections, and wherein the roughened or serrated surface of the insert connector engages with the support walls of the first and second frame sections.
19 . The frame of claim 1 , and further comprising indents located on an element chosen from the insert connector, an inside surface of the insert connector, an outside surface of the insert connector, the support walls of the first and second frame sections, and the sidewalls of the first and second frame sections.
20 . The frame of claim 19 , wherein the indents are configured to engage with an adjacent material chosen from an insert connector, sidewalls of the first and second frame sections, and support walls of the first and second frame sections.