Boltless module support structures and boltless module attachment method
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Solution Overview
Problem
The existing methods for attaching solar panels to support structures using bolts are cumbersome, time-consuming, and prone to errors due to ergonomic challenges, alignment difficulties, and the need for frequent retorquing, which increases costs and safety risks.
Innovation Solution
A boltless module attachment system utilizing interlocking flanges and/or stud and slot components that eliminate the need for bolts, allowing for rapid and secure alignment and installation without torquing, using gravitational force and cap/slot alignment for securement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If bolts are used to attach solar panels to support structures, then secure attachment is achieved, but installation time and complexity increase significantly
Solution Approach 1:
The attachment system is divided into separate functional components: support rails with integrated slots and module frames with integrated connectors. The connectors feature a two-part design with a mounting portion that attaches to the rail and a frame portion that secures to the module, allowing for rapid snap-fit installation without bolts
Solution Approach 2:
The bolt and nut fastening mechanism is completely removed from the attachment system. Instead, the invention uses integrated connectors that snap-fit directly into slots on the support rails, eliminating the need for separate fasteners and torquing operations
Solution Approach 3:
The connector is designed as a unified component that combines the mounting function (attaching to support rail) and frame attachment function (securing module) into a single integrated piece. The support rail also integrates the slot and grounding functions, eliminating the need for separate grounding wires or straps
2Strength
If bolts are used for module attachment, then secure connection is achieved, but the number of parts and device complexity increase
Solution Approach 1:
The support rail serves multiple functions simultaneously: it provides structural support, includes integrated slots for connector attachment, and incorporates grounding capability through the slot design. The connector likewise performs both mounting and frame attachment functions, eliminating the need for separate grounding components
Solution Approach 2:
The invention removes bolts, nuts, washers, and separate grounding components from the system. The attachment mechanism uses only the integrated connectors and slots, reducing the bill of materials to essential components only
3Reliability
If manual bolt torquing is performed, then proper grounding is achieved, but installation cost and time increase
Solution Approach 1:
The torquing operation and separate grounding components are completely removed. The slot design inherently provides grounding continuity through its metal-to-metal contact path, eliminating the need for torquing to ensure electrical connection
Solution Approach 2:
The connector and slot design automatically ensures both mechanical attachment and electrical grounding through their inherent metal-to-metal contact. The system is self-verifying through visual inspection of connector engagement, eliminating the need for torquing verification procedures
4Strength
If bolts are used for attachment, then module securing is achieved, but alignment precision and installation ease deteriorate
Solution Approach 1:
The connector and slot are designed with asymmetric geometries that guide proper alignment during installation. The connector features a shaped interface that fits uniquely into the slot, providing self-alignment and preventing incorrect installation orientations
Solution Approach 2:
The support rails are pre-installed with slots in precise positions during system fabrication. This preliminary positioning eliminates the need for field alignment operations, as the connectors simply need to be snapped into the pre-positioned slots
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution reduces installation time and costs, minimizes defects, and ensures proper electrical grounding without the need for manual torquing, enhancing safety and performance by simplifying the installation process and reducing the risk of bolt loss and misalignment.
Implementation Method 1
allowing for rapid and secure alignment and installation without torquing, using gravitational force and cap/slot alignment for securement
Data Source
AI summary
The present invention provides a boltless module mounting system and a method of installing a boltless module. The system includes at least one module frame containing a module laminate, at least one support structure having support rails, and multiple boltless mounting components. The mounting components attach the module frame to the support rails. The present invention also provides a boltless module mounting system including at least one module having posts and at least one support structure with support rails. The support rails have receiving slots with a receiving hole and two or more slide slots. The posts interlock with the receiving slots. The method includes aligning multiple boltless connectors, lowering a boltless module frame onto a support structure, and sliding the frame to interlock the boltless connectors.