Collapsible Spacer with Cam Mechanism for Solar Panel Gap Setting
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Solution Overview
Problem
The removal of temporary spacers between solar panels is inefficient due to compressive forces and difficulty in handling, especially on steep roofs, leading to increased risk of installer falls and reduced operational efficiency.
Innovation Solution
A collapsible spacer with a handle and expandable/collapsible clip that eases removal by reducing friction through a mechanism that collapses under panel pressure, featuring a handle for easy gripping and a clip that expands to set the gap between panels.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a rigid spacer is used to maintain gap between solar panels, then consistent gap sizing is achieved, but the spacer becomes difficult to remove due to compressive forces and friction
Solution Approach 1:
The spacer transitions from a rigid state during installation (maintaining gap) to a collapsible state during removal. The collapsible portion allows the spacer to compress under panel weight and then be easily removed by collapsing it to a smaller profile, resolving the contradiction between maintaining precision and enabling easy operation.
Solution Approach 2:
The spacer is divided into a rigid portion (for maintaining gap dimensions) and a collapsible portion (for easy removal). This segmentation allows the spacer to fulfill both functions: the rigid portion ensures consistent gap sizing while the collapsible portion enables easy removal by reducing friction and compressive force contact.
2Productivity
If installers work on steep roofs to install solar panels, then installation capacity is increased, but the risk of falls increases due to difficult spacer removal requiring outward pulling force
Solution Approach 1:
The collapsible spacer allows installers to work efficiently on steep roofs by enabling easy removal without requiring dangerous outward pulling forces. The spacer can be removed by collapsing it inward, allowing the installer to maintain balance and grip while working on inclined surfaces.
Solution Approach 2:
The compressive force that normally creates friction and makes removal difficult is converted into a beneficial feature. The same panel weight that compresses the spacer during installation becomes the mechanism for easy removal when the installer collapses the spacer, turning a harmful friction force into a helpful compression-removal mechanism.
3Manufacturing precision
If a rigid spacer is used between solar panels, then gap maintenance is effective, but the installer must reach horizontally across panels to remove it, compromising balance
Solution Approach 1:
The spacer is segmented into rigid and collapsible portions, allowing the installer to collapse it vertically rather than pull it horizontally. This eliminates the need to reach across panels, maintaining the installer's balance and proper posture while still achieving consistent gap maintenance during installation.
4Reliability
If installers wear thick gloves for protection while working, then safety is improved, but dexterity to grasp and remove spacers is reduced
Solution Approach 1:
The collapsible portion of the spacer acts as a flexible element that can be easily grasped and collapsed even through thick gloves. The flexible nature of this portion provides sufficient grip surface and mechanical advantage, allowing installers to maintain both protective glove wear and operational dexterity.
Data Source
AI summary
A spacer which can be temporarily inserted between two panels, such as solar modules, prior to securing the panels; such that a consistent gap is established between the panels; and a method for using said spacer. The spacer includes a collapsing feature which relieves pressure on the spacer from the adjacent panels for easier removal of the spacer. The spacer may use a cam feature to collapse its size prior to removal.