UP: Steely determination
Gregg Patterson: The one thing in a PV system that hasn’t changed or seen any real innovation in the 60-plus years that solar has been around is the module frame. It is the only component in an entire PV project that hasn’t seen radical improvements or innovation, and cost reductions have only come with significant performance loss.
We saw a big opportunity here. For a lot of reasons, which we have demonstrated, steel is just a better solution overall for module frames. But there were two fundamental issues to solve: corrosion and the weight. Because steel is much heavier than aluminum.
If you could solve those, steel is stronger, it’s more fatigue resistant, it’s much more abundant, and much more regionally available than aluminum. It delivers a compelling value proposition.
It’s taken years to figure out but we have solved both. The corrosion is solved because there are market validated corrosion coatings used in construction and automotive that are much better than galvanization, and have been validated as well for solar projects.
The weight was the biggest technical challenge: to use very little steel and achieve the required structural performance for a module frame. That’s where we came up with the name Origami, because you need to create a folded cross section that achieves the structural performance and maximizes the strength while using very little steel.
Looking at the weight first of all, how do your steel frames compare to typical aluminum products?
They’re not the same but we understand the weight gain. For a module that weighs 35 kg, we’ll add about 2 kg compared to the same module with an aluminum frame – that’s for a large, utility-scale type module.
We’re working with tracker and racking companies and that weight gain is in the noise. It’s immaterial to project design and installation, and steel can double the structural performance. That is two times the load at which a module breaks. This translates to significantly higher wind ratings and safety margins.
That performance enables much lower cost overall. Modules have grown in size by 44%, on average, in the last five years and manufacturers looking to cut costs pull 35% to 40% of the aluminum out of the frame and we’re seeing breakage all over the place.
To adapt, tracker companies have to use more expensive, longer rails to make up for the structural weaknesses that aluminum frames are showing. That’s only a partial and not very efficient solution. It just moves cost from the module to the mounting system.
A better frame is the most cost-effective solution and if you threw that much more aluminum back into the frames, the cost increase would be material. Steel can do it much more cost effectively.
On the residential side they’re a lot more worried about the weight, but a residential module is smaller as well. For now, we are focused on the utility-scale segment but we are developing a residential frame where the weight gain, because of the smaller size, is going to be probably a kilogram or less, and engineers are very comfortable with that.
What scale are you producing frames at today and what is the plan for scale-up?
Now we are building and creating this market. We expect to start shipping to customers in Q2 of 2025.
Customized/OEM/ODM Service
HomSolar Supports Lifepo4 battery pack customization/OEM/ODM service, welcome to contact us and tell us your needs.
HomSolar: Your One-stop LiFePO4 Battery Pack & ESS Solution Manufacturer
Our line of LiFePO4 (LFP) batteries offer a solution to demanding applications that require a lighter weight, longer life, and higher capacity battery. Features include advanced battery management systems (BMS), Bluetooth® communication and active intelligent monitoring.
Customised Lithium Iron Phosphate Battery Casing
ABS plastic housing, aluminium housing, stainless steel housing and iron housing are available, and can also be designed and customised according to your needs.
HomSolar Smart BMS
Intelligent Battery Management System for HomSolar Energy Storage System. Bluetooth, temperature sensor, LCD display, CAN interface, UART interface also available.
Terminals & Plugs Can Be Customized
A wide range of terminals and plugs can be customised to suit the application needs of your battery products.
Well-designed Solutions for Energy Storage Systems
We will design the perfect energy storage system solution according to your needs, so that you can easily solve the specific industry applications of battery products.
About Our Battery Cells
Our energy storage system products use brand new grade A LiFePO4 cells with a battery lifespan of more than 4,000 charge/discharge cycles.
Applications in Different Industries
We supply customized & OEM battery pack, assemble cells with wiring, fuse and plastic cover, all the cell wires connected to PCB plug or built BMS.
Applications: E-bike, Electric Scooter, Golf Carts, RV, Electric Wheelchair, Electric Tools, Robot Cleaner, Robot Sweeper, Solar Energy Storage System, Emergency Light, Solar Power Light, Medical Equipment, UPS Backup Power Supply.
We can provide you with customized services. We have the ability to provide a vertical supply chain, from single cells to pack/module and to a complete power solution with BMS, etc.
HomSolar (Shenzhen) Technology Co., Ltd
