Methods and Systems for Folded Frame Solar Panels
Embodiments of the present invention may provide an elongated single piece of framework ( 59 ) which may be bent around a corner ( 46 ) perhaps for form an about 90 degree angle ( 61 ). An elongated single piece of framework ( 59 ) may have a first end ( 49 ) and a second end ( 50 ) which may be joined to each other or may be joined to other ends of a separate framework. A partial frame ( 48 ) or even a rectangular panel framework ( 3 ) may be created from at least one of an elongated single piece of framework which may frame a solar panel.
1 . A method for enclosing a solar panel comprising the steps of:
providing an elongated single piece of panel framework;
bending said elongated single piece of said panel framework around a corner of a rectangular photovoltaic laminate to create an about 90-degree angle in said elongated single piece of said panel framework;
placing said bent elongated single piece of panel framework around said corner of said photovoltaic laminate; and
creating at least a partial frame around said corner of said rectangular photovoltaic laminate with said bent elongated single piece of panel framework.
2 . The method according to claim 1 and further comprising a step of providing a furrow in said elongated single piece of said panel framework; and
wherein said step of bending said elongated single piece of said panel framework around a corner of said rectangular photovoltaic laminate to create said about 90-degree angle in said elongated piece of said panel framework comprises a step of bending said elongated single piece of said panel framework at said furrow and around said corner of said rectangular photovoltaic laminate to create said about 90-degree angle in said elongated single piece of said panel framework.
3 . The method according to claim 1 wherein said elongated single piece of said panel framework comprises a first end and a second end.
4 . The method according to claim 3 wherein said elongated single piece of said panel framework comprises a length of about a perimeter of said rectangular photovoltaic laminate.
5 . The method according to claim 1 and further comprising the steps of:
bending said elongated single piece of said panel framework at three different positions in said elongated single piece of said panel framework to create three about 90-degree angles at each of said positions;
creating a rectangular panel framework from said elongated single piece of panel framework with said three about 90-degree angles;
enclosing said rectangular panel framework around said rectangular photovoltaic laminate wherein each of said three about 90-degree angles encase a corresponding corner of said rectangular photovoltaic laminate; and
connecting a first end of said elongated single piece of to a second end of said elongated single piece of said panel framework.
6 . The method according to claim 1 and further comprising a step of connecting a first end of a first panel framework to an end of a second panel framework to form a rectangular panel framework.
7 . The method according to claim 5 wherein said step of connecting ends of a panel framework comprises a step of connecting said ends of said panel frameworks at a corner.
8 . The method according to claim 7 wherein said step of connecting said ends of said panel frameworks comprises the steps of:
providing a first attachment protrusion at a first end of said panel framework;
providing a second attachment protrusion at a second end of said panel framework or an end of a second panel framework;
placing said first end to said second end to create a corner; and
joining said first attachment protrusion at said first end with said second attachment protrusion at said second end.
9 . The method according to claim 4 and further comprising the steps of:
bending said elongated single piece of said panel framework at four different positions in said elongated single piece of said panel framework to create four about 90-degree angles at each of said positions;
creating a rectangular panel framework from said elongated single piece of panel framework with said four about 90-degree angles;
enclosing said rectangular panel framework around said rectangular photovoltaic laminate wherein each of said four about 90-degree angles encase a corresponding corner of said rectangular photovoltaic laminate; and
connecting a first end of said elongated single piece of to a second end of said elongated single piece of said panel framework at a non-corner.
10 . The method according to claim 6 wherein said step of connecting ends of a panel framework comprises a step of connecting said ends of said panel frameworks at a non-corner.
11 . The method according to claim 5 wherein said step of connecting said first end to said second end further comprises a step chosen from:
connecting said first end to said second end by overlapping edges of each end; and
connecting said first end to said second end at a junction and adding a bracket over said junction.
12 . The method according to claim 1 wherein said elongated single piece of said panel framework comprises a side frame wall and a bottom frame lip; wherein said bottom frame lip is located perpendicular to said side frame wall.
13 . The method according to claim 12 and further comprising a step of providing a notch in said bottom frame lip of said elongated single piece of said panel framework.
14 . The method according to claim 13 and further comprising the steps of:
placing said notch below where said about 90-degree angle will be created in said step of bending said elongated single piece of said panel framework around said corner of a rectangular photovoltaic laminate to create an about 90-degree angle in said elongated single piece of said panel framework; and
meeting said edges of said notch in said bottom frame lip to create a bottom frame lip bend junction when said about 90-degree angle in said elongated single piece of said panel framework is created.
15 . The method according to claim 14 and further comprising a step of securing said bottom frame lip bend junction.
16 . The method according to claim 15 wherein said step of securing said bottom frame lip junction comprises a step of overlapping an offset of said bottom frame lip.
17 . The method according to claim 15 wherein said step of securing said bottom frame lip junction comprises the steps of:
providing a first attachment protrusion at a first edge of said notch in said bottom frame lip;
providing a second attachment protrusion at a second opposite edge of said notch in said bottom frame lip; and
joining said first attachment protrusion at said first edge with said second attachment protrusion at said second edge when said bottom frame lip junction is created.
18 . The method according to claim 15 wherein said step of securing said bottom frame lip junction comprises a step of adding a corner bracket to said bottom frame bend lip junction.
19 . The method according to claim 1 and further comprising a step of attaching said framework to a racking.
20 . The method according to claim 19 wherein said step of attaching said framework to said racking comprises the steps of:
providing a fissure in said framework;
providing an extrusion in said racking;
mating said extrusion through said fissure in said framework; and
securing said framework to said racking with said extrusion in said fissure.
21 - 34 . (canceled)