U.S. patent application number 11/744281 was filed with the patent office on 2008-02-14 for solar roof tile.
This patent application is currently assigned to BP Corporation North America Inc.. Invention is credited to Dinesh S. Amin, Paul L. Garvison, George J. Kelly, Neil V. Placer, Donald B. Warfield.
Application Number | 20080035140 11/744281 |
Document ID | / |
Family ID | 38460703 |
Filed Date | 2008-02-14 |
United States Patent
Application |
20080035140 |
Kind Code |
A1 |
Placer; Neil V. ; et
al. |
February 14, 2008 |
Solar Roof Tile
Abstract
A frame system suitable for mounting a solar module on a roof,
the frame system comprising at least one frame comprising an upper
frame member, a lower frame member a right-side frame member, a
left-side frame member, at least one projecting member that is
attached to or is an integral part of at least one of the side
frame members, and projecting in a direction toward or
substantially toward the fewer frame member; and a batten
comprising a recess for engaging the projecting member of the
frame. The frame optionally comprises a means for affixing the
frame to another frame.
Inventors: |
Placer; Neil V.; (Frederick,
MD) ; Amin; Dinesh S.; (Clarksburg, MD) ;
Kelly; George J.; (Mt. Airy, MD) ; Warfield; Donald
B.; (Woodbine, MD) ; Garvison; Paul L.;
(Frederick, MD) |
Correspondence
Address: |
CAROL WILSON;BP AMERICA INC.
MAIL CODE 5 EAST, 4101 WINFIELD ROAD
WARRENVILLE
IL
60555
US
|
Assignee: |
BP Corporation North America
Inc.
Warrenville
IL
|
Family ID: |
38460703 |
Appl. No.: |
11/744281 |
Filed: |
May 4, 2007 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
60808918 |
May 26, 2006 |
|
|
|
60803427 |
May 30, 2006 |
|
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Current U.S.
Class: |
126/622 |
Current CPC
Class: |
H02S 30/10 20141201;
Y02B 10/10 20130101; F24S 2020/13 20180501; H02S 20/25 20141201;
F24S 25/20 20180501; Y02E 10/47 20130101; F24S 25/632 20180501;
Y02E 10/50 20130101; Y02B 10/20 20130101 |
Class at
Publication: |
126/622 |
International
Class: |
E04D 13/18 20060101
E04D013/18 |
Claims
1. A frame suitable for a solar module comprising: an upper frame
member, a lower frame member, a right-side frame member, a
left-side frame member, and at least one projecting member attached
to or an integral part of at least one of the side frame members,
and projecting in a direction toward or substantially toward the
lower frame member; each of the frame members having at least an
outer side, an inner side, an upper portion running along at least
part of the length of the member, and a lower portion running along
at least part of the length of the member.
2. The frame of claim 1 wherein each of the frame members are
initially separate pieces and are joined to form the frame.
3. The frame of claim 1 wherein the outer side of each of the side
frame members has a portion shaped to engage, in an interlocking
manner, an edge of a roof tile.
4. The frame of claim 3 wherein the portion shaped to engage the
edge of a roof tile is U shaped.
5. The frame of claim 1 wherein a projecting member is in the shape
of a tab.
6. The frame of claim 1 wherein a projecting member is located on
the lower portion of at least one of the side frame members and is
positioned parallel to the direction of the side frame member.
7. The frame of claim 1 further comprising a means for affixing one
frame to another frame.
8. The frame of claim 7 wherein the means for affixing one frame to
another frame is located on the upper frame member.
9. The frame of claim 7 wherein the means for affixing one frame to
another frame is a threaded bolt affixed to the frame.
10. The frame of claim 8 wherein the upper frame member has a right
end adjacent the right frame member and a left end adjacent the
left frame member and the means for affixing one frame to another
frame is positioned at or near the left end of the upper frame
member.
11. The frame of claim 1 wherein the side frame members have upper
ends and lower ends and the projecting member is positioned on the
side frame member closer to the lower end than to the upper
end.
12. The frame of claim 1 wherein the side frame members have upper
ends and lower ends and an opening in the lower portion of the side
frame member positioned closer to the upper end than to the lower
end of the side frame member.
13. A frame system comprising: at least one frame suitable for a
solar module, wherein the frame comprises an upper frame member; a
lower frame member, a right-side frame member, a left-side frame
member, at least one projecting member attached to or an integral
part of at least one of the side frame members, and projecting in a
direction toward or substantially toward the lower frame member;
and a batten comprising a recess for engaging the projecting member
of the frame.
14. The frame system of claim 13 wherein the batten is J
shaped.
15. The frame system of claim 13 wherein the batten is shorter in
length than the lower member of the frame.
16. The frame system of claim 13 wherein the batten is shorter in
length than the lower member of the frame.
17. A method for installing a framed solar module on a pitched roof
comprising: (a) attaching a batten to the roof at a desired
location on the roof, where the batten comprises a recess having an
open portion, and where the batten is attached to the roof so that
the open portion of the recess faces an upper portion of the
pitched roof, and (b) positioning a solar module framed with the
frame of claim 1 on the roof so that at least one projecting member
of the frame engages the recess of the batten.
18. The method of claim 17 wherein the positioning comprises moving
the framed solar module in a downward direction to engage the
projecting member with the batten.
19. The method of claim 17 wherein the frame is positioned next to
and in contact with an adjacent roof tile.
20. The method of claim 17 wherein after step (b) the frame is
affixed to the roof.
21. The method of claim 17 wherein at least two battens are
attached to the roof and the battens are affixed to the roof with a
gap between the battens to provide for the passage of water.
22. A solar module roof tile comprising a solar module framed
within the frame of claim 1.
23. A frame suitable for a solar module comprising: an upper frame
member, a lower frame member, a right-side frame member, a
left-side frame member, each of the frame members having at least
an outer side, an inner side, an upper portion running along at
least part of the length of the member, and a lower portion running
along at least part of the length of the member; and a means for
affixing a frame to another frame.
24. The frame of claim 23 wherein the means for affixing one frame
to another frame is located on the upper frame member.
25. The frame of claim 23 wherein the means for affixing one frame
to another frame is a threaded bolt affixed to the frame.
26. The frame of claim 23 wherein the upper frame member has a
right end adjacent to right frame member and a left end adjacent
the left frame member and the means for affixing one frame to
another frame is positioned at or near the left end of the upper
frame member.
27. The frame of claim 7 further comprising a ground wire attached
to the means for affixing.
28. The method of claim 17 where in the frame further comprises a
means for affixing a frame to an adjacent frame and each frame is
affixed to an adjacent frame in a row of frames.
29. The method of claim 28 further comprising attaching at least
one ground wire to at least one frame, wherein the ground wire is
attached to the means for affixing the frames.
30. The frame system of claim 13 when a solar module is framed
within the frame.
31. A solar module roof tile comprising a solar module framed
within the frame of claim 23.
Description
FIELD OF THE INVENTION
[0001] The present invention relates to a photovoltaic or solar
module in the form of a tile that can be mounted on a roof or other
structure. The present invention relates to a method for mounting
such solar modules on a roof or other structure. The present
invention also relates to a solar module roofing system and a
method for installing such system.
BACKGROUND OF THE INVENTION
[0002] in recent years, considerable advances have been made in
using photovoltaic cells or the like to directly convert solar
energy into useful electrical energy. Typically, a plurality of
photovoltaic cells are encased between a transparent cover sheet
(e.g. glass, plastic, etc.) and a transparent or opaque backsheet,
to form flat, rectangular-shaped modules (sometimes also called
"laminates") of a manageable size (e.g. 21/2'.times.5'). These
photovoltaic or solar modules are usually equipped with a frame
around the perimeter of the module constructed of, for example,
aluminum to provide strength, and also to provide a convenient
means with which to attach the module to a roof or other structure.
Such modules are then mounted on an existing roof or other
structure in a manner so that they are exposed to the sun. For
example, framed solar modules are bolted or clamped onto separate
support structures, e.g. "racks", which, in turn, are securely
bolted or screwed directly into the roof. Although such arrangement
provides for the desired conversion of sunlight into electricity to
be used for a home or for some other purpose, such installations
are essentially, an add-on to an existing building or other
structure. Since solar electricity is increasing in use, there is a
need to have the solar module become part of the building or other
structure and preferably where the solar module functions in a
manner in addition to producing solar electricity. For example,
such building integrated solar modules can function as a facade or
window for the structure, or can be or form part of the actual roof
of a building, such as a home.
[0003] One building integrated solar module that has been developed
is a solar module in the form of a roof tile. In one such solar
module roof tile, a solar module is sealed into a frame, such as a
frame made of aluminum, and the left and right sides of the
generally square or rectangular-shaped frame are constructed so
that they have a shape that corresponds to the shape of the edges
of a roof tile, such as a terra cotta or concrete roof tile. Thus,
when the roof is constructed, one or a number of such solar module
roof tiles are placed on the roof along with the ordinary roof
tiles and the solar module roof tiles fit in the roof structure in
the same manner as the roof tile and function as a roof tile, but
have the ability to generate electricity from exposure to the sun.
Such solar roof tiles are attractive because they are integrated
into the roof structure rather than being an add-on, and they
generate electricity while also functioning as a roofing material.
Because they are part of the roof rather than being an add on, such
solar roof tiles are aesthetically appealing.
[0004] However, it would be desirable to be able to install solar
module roof tiles in a manner that is easy for the installer and
yet form a durable, rain, wind and other weather resistant layer on
the roof. The present invention provides for such a solar module
roof tile and a method for its installation.
BRIEF SUMMARY OF THE INVENTION
[0005] This invention is a frame suitable for framing a solar
module where the frame comprises an upper frame member, a lower
frame member, and right-side frame member, a left-side frame
member, and at least one projecting member attached to or an
integral part of at least one of the side frame members, and where
the projecting member projects in a direction toward or
substantially toward the lower frame member. This invention is also
a solar roof tile wherein a solar module is incorporated into such
frame. This invention is also a frame system suitable for mounting
a solar module on a roof, the frame system comprising at least one
frame comprising an upper frame member, a lower frame member, a
right-side frame member, a left-side frame member, at least one
projecting member that is attached to or is an integral part of at
least one of the side frame members, and projecting in a direction
toward or substantially toward the lower frame member; and a batten
comprising a recess for engaging the projecting member of the
frame.
BRIEF DESCRIPTION OF THE FIGURES
[0006] FIG. 1 is a three dimensional view of a solar module roof
tile in accordance with an embodiment of this invention on a
pitched roof along with regular concrete roof tiles.
[0007] FIG. 2 is a three dimensional view of a frame of a solar
module roof tile in accordance with an embodiment of this invention
where the frame members are shown in disassembled form.
[0008] FIG. 3 is a three dimensional view of an embodiment of the
projecting members and a batten of this invention.
[0009] FIG. 4 is a section view of FIG. 1 showing two solar module
roof tiles in accordance with an embodiment of this invention on a
pitched roof along with two regular concrete roof tiles.
[0010] FIG. 5 is a section view of a right frame member in
accordance with an embodiment of this invention.
[0011] FIG. 6 is a section view of a left frame member in
accordance with an embodiment of this invention.
[0012] FIG. 7 is a three dimensional view of a portion of an upper
frame member in accordance with an embodiment of the frame of this
invention.
DETAILED DESCRIPTION OF THE INVENTION
[0013] While the invention will be described in connection with
specific preferred embodiments, it will be understood that this
invention is not limited thereto. On the contrary, the invention is
intended to cover all alternatives, modifications, and equivalents
included within the spirit and scope of the invention as defined by
the appended claims.
[0014] Referring now to the drawings, which are not necessarily
drawn to scale and where the same elements are numbered the same in
the drawings, FIG. 1 shows a solar module roof tile 5 in accordance
with this invention mounted on roof 10. Solar module roof tile 5
has a frame 6 and a solar module laminate 8 within such frame.
Solar module laminate 8 has a plurality of individual solar cells 9
(only one numbered for clarity). Methods for manufacturing solar
module laminates suitable for use in the solar module roof tile of
this invention are well known by those of skill in the art. Any
type of solar module laminate can be used to construct the solar
module roof tile of this invention. For example, solar module
laminates containing solar cells made from mono- or
multi-crystalline silicon wafers, or thin film solar modules such
as those comprising amorphous silicon photovoltaic elements cadmium
telluride/cadmium sulfide photovoltaic elements or CIS photovoltaic
elements can be used. Preferably, however, the solar modules do not
have photovoltaic elements positioned in the module where they
would be under another solar module roof tile or under an ordinary
roof tile when the solar roof tile is installed on a roof.
[0015] Roof 10 has mounted thereon a plurality of ordinary concrete
tiles 15 (only one numbered for clarity), where one such concrete
tile 15a, drawn in partial form, is adjacent to solar module roof
tile 5. This illustrates how the solar module roof tile of this
invention engages an adjacent concrete roof tile, is integrated
into the roof structure, and forms part of the roof. It is to be
understood that when all the solar roof tiles are installed, the
roof 10 would normally contain a plurality of solar roof tiles and,
optionally, a plurality of ordinary roof tiles to form the complete
roof. Solar module tile roof batten 20 in accordance with this
invention and standard roof battens 25 are positioned on and
affixed to roof 10. The concrete roof tiles 15 have a groove or
channel 16 that engages roof batten 25. The roof battens 25 assist
with lining up the roof tiles on the roof and assist with retaining
the roof tiles on the pitched roof. FIG. 1 shows how the left-side
frame member 30 of frame 6 engages solar module tile batten 20. The
upper solar module roof tile 5a in FIG. 1 is not drawn in detail.
However, it demonstrates how the solar module roof tiles of this
invention overlap as do regular tiles to form a tiled roof.
[0016] FIG. 2 shows the solar module roof tile of this invention
where frame 6 is in disassembled form. Frame 6 has left-side frame
member 45. Also, shown in FIG. 2 is solar module laminate 8.
Individual solar cells 9, however, are not presented in FIG. 2.
Each frame member 30, 35, 40 and 45 has a channel 55 along the
inside of each frame member. When the solar module roof tile is
assembled, the channel 55 receives the respective edges of solar
module laminate 8. Typically, a suitable sealant is used to seal
the edge of solar module laminate 8 within channel 55. Any suitable
sealant can be used such as, for example, a butyl sealant. In this
particular embodiment of frame 6 (FIG. 1) the frame is assembled by
screws or bolts that hold the respective frame members to each
other. Details of such frame assembly are described hereinbelow.
FIG. 2 also shows how projecting members 60 are shaped so as to be
able to engage batten 20. Projecting member 60 are located along
the lower portion of frame side members 30 and 35 and project in a
direction toward or substantially toward the lower frame member 45
in the fully assembled frame. There is a space or slot 61 between
projecting members 60 and the lower portions of the side frame
members 30 and 35. The lower frame member 45 is referred to as the
lower frame member because when a solar module roof tile made with
such frame is installed on a pitched roof, the lower frame member
is the frame member that is closer to the bottom of the roof.
Although shown in the figures as a "tab" shaped member, it is to he
understood that projecting member 60 can be any suitable shape. For
example, it can be a rod or post with a round or other
cross-sectional shape. The projecting member can extend or project
from the side members so it is parallel to the side member on it
can project at an angle from the side member. As will be described
in more detail below, projecting member 60 engages the solar module
tile pattern 20 by projecting into the open recess 24 in the batten
20. Thus, a projecting member having any suitable shape that will
accomplish such engagement will be equivalent to the "tab" shaped
projecting member 60 as shown in the figures. The projecting member
can, be an integral part of the frame side member as shown in the
figures, or it can be a separate piece that is attached in some
manner, for example, by screws or bolts or rivets, to the frame
side member. Solar module tile batten 20 has a --"J"
cross-sectional shape in the figures. The "J" shape is defined by
upper flange 21, wall section 22 and base section 23. The recess 24
is within such "J" shaped batten. While a "J" shaped batten is
shown in this embodiment of the invention, it is to be understood
that the solar module tile batten can have any suitable shape that
provides for a recess that engages projecting member 60. In
operation, projecting member 60, when engaged with the solar module
tile batten 20 that is affixed to a roof, presents the solar module
roof tile from sliding down a pitched roof during the installation
process. Also, the engagement of the projecting member within the
recess of solar module tile batten 20 prevents the solar tile from
being lifted off the roof in the event of a strong wind. More
specifically, with respect to the embodiment shown in the figures,
when the solar module roof tile and batten 20 are installed on a
roof, tab-shaped projection 60 would engage flange 21 on batten 20
if the solar module roof tile were to be lifted from the roof by
wind.
[0017] FIG. 3 shows an expanded view of how projecting member 60
engages solar module tile batten 20 when the solar module roof tile
is installed on a roof. In FIG. 3 only the relevant portions of the
left frame member 30 and right frame member 35 are presented.
However, FIG. 3 also illustrates how, in this embodiment, the
tab-shaped projection 60 fits into recess 24 of solar module tile
batten 20 and how upper flange 21 of the solar roof batten fits
into opening or slot 61 on frame side members 30 and 35, thereby
preventing the solar module roof tile from being uplifted in the
event of a strong wind.
[0018] FIG. 4 is a section view of FIG. 1. FIG. 4 shows how an
upper solar module roof tile 5a overlaps with a lower solar roof
tile 5, end how the solar roof tile 5 overlaps with a regular roof
file 15. FIG. 4 also shows how preheating member 60, located on
lower portion 65 of left side frame member 30, engages solar module
tile batten 20. FIG. 4 also shows that projection 60 is located on
left side frame member 30 closer to lower end 70 of left frame
member 30 than to upper end 75 of left side frame member 30.
Preferably, projecting member 60 is located closer to the lower end
of the solar module roof tile than to the upper end because this
provides for greater leverage in the event that wind acts to force
an uplift of the solar module roof tile. Opening 80 in the left
side frame member and corresponding opening in the right side frame
member provides clearance for a roof batten 25 to pass under the
solar roof tile. Without such clearance, the respective section of
the roof batten would need to be removed thereby complicating the
installation of the solar roof tiles on the roof. Solar module tile
batten 20 can have one or more pre-formed holes (not shown in
figure) in base 23 to receive screws, bolts, nails or other means
for taste nine the batten to the roof. When such batten is fastened
to a roof, it is preferable to apply an adhesive or sealant to the
roof where the bolt, nail, screw, or other means for fastening
enters the roof to fasten the batten to the roof. Such adhesive or
sealant provides for waterproofing. Solar module roof batten 20 can
optionally have one or mere holes or other openings 81 (for
clarity, only one such opening is numbered in FIG. 1) in the wall
section 22 of the batten 28 to allow for the passage of water so
that water does not collect end remain in recess 24. The solar
module batten can be made of any suitable material such as, for
example, aluminum or other metal, or one or more polymeric or resin
materials. It is in be understood that the solar module tile batten
of this invention can be any suitable length. For example, each
batten can have a length that is shorter, preferably slightly
shorter, than the length of the lower frame member. The solar
module tile battens, preferably those that are shorter than the
length of the lower frame member, can be mounted on a roof so that
there is a space or gap between the battens. Such space or gap
provides for the passage of water.
[0019] FIG. 5 shows a season view through the right side frame
member and an adjacent concrete tile engaged with the right aloe
frame member. FIG. 6 shows a section view through the left side
frame member and an adjacent concrete tile engaged with the left
side frame member. FIGS. 5 and 6 illustrate how the outer portion
of side frame members 35 and 40 engage a standard concrete tile to
form a seam between the solar module roof tile and the standard
roof tile. The profile of the frame side members 35 and 40 as
presented in FIGS. 5 and 6 is on particular profile. However, it is
to be understood that such profile can be changed to accommodate
the different types of roof tiles. "Screw boss" holes 90, 93, 95,
and 97 can be used to attach the lower frame member to the side
frame members by inserting a screw or bolt through holes in the
lower frame member and then into the corresponding screw boss.
Corresponding screws boss holes located on the opposite side of the
side frame member (not all show in FIGS. 5 and 6) can be used for
attaching the upper frame member to the side frame members.
[0020] FIG. 7 shows two solar roof tiles of this invention in the
process of being joined together or affixed to each other by
threaded stud 100 and nut 105. Threaded stud 100 is attached to
upper frame member 40 of first solar roof tile 5 and passes through
opening 110 in the upper frame member 40 of second solar module
roof tile 5. The two solar modules are thereafter attached or
affixed to each other by tightening the nut 105 on threaded stud
100. Although, as shown in FIG. 7, a threaded stud is the means for
affixing one frame to another frame, it is to be understood that
any suitable means for affixing such frames can be used. For
example, one or more of a rivet, screw, bolt, weld, clip, clamp or
the like, can also be used. It is not however, necessary to attach
one such solar roof tile to another in such manner or any other
manner. However, it is advantageous to attach adjacent solar
modules tiles if their frames are made of an electrically
conducting material such as a metal. This allows for a convenient
way to electrically ground the frames of the solar roof tiles and
thereby reduce the possibility of causing an electrical shock.
Although not shown in the figures, an electrical ground wire can be
attached to a frame for electrically grounding the frame or
collection of connected frames, for example, a row of solar module
roof tiles, of this invention. Such grounding wire can be attached
to one or more frames by the threaded stud 100. For example, one
end of the ground wire can end in a lug and such lug attached to
the threaded stud using a suitable nut. The other end of the wire
is properly connected to ground. Aluminum, for example, is one of
the preferred materials for making the frames of this invention
although other metals, and other materials such as one or more
polymeric or resin materials, can be used to construct the frame.
Screws or bolts 115 shown in FIG. 7 secure upper frame members 40
to side frame members 30 and 35. Opening 120 with grommet 125 in
upper frame member 40 provides a passage way for the solar module
output wires 140 and 145 so that the solar module roof tiles can be
electrically connected in a desired manner. Flange 130 on upper
frame member 40 rests on roof surface 10 (FIG. 1) when the solar
module roof tile is mounted on a roof. Screws or bolts or other
suitable means can be used to affix the flange and thus the solar
roof tile to the roof. Flange 130 can have preformed holes or other
openings (such holes or openings not shown in the Figure) to
receive such bolts, screws or other means for affixing the flange
to a roof. Flange 130 can be constructed so that it is disposed at
an angle relative to the upper frame member 40. The angle is
suitably selected so that the flange will lay flat on a pitched
roof to which it is attached. As with attaching the solar module
tile battens to the roof, any penetrations in the roof that are
made as a result of affixing the flange 130 to a roof can be sealed
with a suitable sealant.
[0021] The solar module roof tiles of this invention are easily
installed on a pitched roof. The installation is simplified because
of the projecting member and the solar module roof batten. In the
preferred installation method, one or more solar module roof
battens are affixed to the roof in a desired pattern corresponding
to the eventual placement of the solar roof tiles on the roof. As
discussed above, a space or gap can be provided between adjacent
battens during their installation on a roof to allow for the
passage of water. The solar module roof tile is placed on the roof
in the desired location either adjacent to another solar module
roof tile or a standard roof tile so that the side member of the
solar module roof tile overlaps and engages with the side member of
the adjacent solar module roof tile or the side of a standard roof
tile. When the solar module roof tile is placed on the roof the
projecting members located on the side members of the solar module
roof tile are engaged with the solar module roof batten so that the
batten prevents the solar module roof tile from sliding down the
roof. The solar module roof tile can thereafter be permanently
affixed to the roof as described above by using bolts, screws or
other fastening means. Thus, the solar module roof tiles of this
invention can be conveniently attached to a roof without having to
otherwise hold the solar module roof tile by hand or by some other
means. This greatly aids the installation of the solar roof tiles.
This installation can be repeated to install the desired number of
solar module roof tiles in rows or in an array on a roof. Solar
modules generally have two electrical output leads 140 and 145 that
exit the solar module through an electrical junction box located on
the back of the solar module (junction box not shown in the
figures). Before permanently affixing the solar module to the roof,
such electrical leads are preferably positioned so that they exit
opening 120 in upper frame member 40. The electrical lead from one
solar roof tile can then be connected with the appropriate
electrical lead form an adjacent solar module roof tile in the
desired manner. Prior to mounting the solar module roof tiles of
this invention on a roof, the roof is preferably covered with an
asphalt-based felt and then with a layer of fireproof material such
as Versashield.RTM. or other suitable fireproofing material.
[0022] As set forth above, the frame of this invention can be made
of a metal such as aluminum. However, other suitable metals can be
used to construct the frame. If made of aluminum or other metal
that can be extruded, the upper, lower and side members of the
frame can be extruded in the desired shape, and the projecting
member can be formed by removing portions of the frame member to
provide for such projecting member. However, it is not necessary
for the frame of this invention to be constructed of separate
members. It can, for example, be one piece such as a single unit
manufactured with the upper, lower and side members attached. Such
a frame can be made by an injection molding procedure using a
suitable polymeric or resin material.
* * * * *