Expandable Torque Tube Splice for Wind Load Distribution

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Solution Overview

Problem

Solar power systems face structural deflection, bending, or failure under high wind loads due to inadequate load distribution at connections and joints, leading to inefficiencies and potential damage.

Innovation Solution

An expandable splice with beveled corner panels that transitions between a narrow configuration for easy insertion into a support channel and an expanded configuration to distribute loads along the length of the support structure, preventing warping or bowing by securing side panels against the inner surface of the torque tube.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If additional support is applied to the array of solar modules or the specific point of attachment, then the local strength at connections and joints is improved, but the load is not distributed sufficiently along the length of the torque tube to prevent distortion or bending

Engineering Contradiction:

Improvelocal strength at connectionsVSAvoidload distribution along torque tube

Core Design Contradiction:

StrengthVSReliability

Solution Approach 1:

The splice is divided into multiple panels (first side panel, second side panel, top panel, bottom panel) that can independently expand and contact different sections of the torque tube, distributing the reinforcement function across multiple segments rather than concentrating it at a single point

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The splice transitions from a narrow configuration to an expanded configuration by moving panels in multiple directions (first side panel moves outward, second side panel moves outward, top and bottom panels expand), adding dimensional complexity to achieve better load distribution along the torque tube length

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

2Strength

If the splice is designed in an expanded configuration to provide additional strength, then the support structure resistance to wind loads is improved, but the difficulty of insertion into the support channel increases

Engineering Contradiction:

Improvesupport structure resistanceVSAvoidinsertion ease

Core Design Contradiction:

StrengthVSEase of operation

Solution Approach 1:

The splice is designed with dynamic expandability, transitioning from a compact narrow configuration for easy insertion to an expanded configuration for reinforcement. The panels can move between positions, allowing the structure to adapt its form based on operational requirements

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The splice panels are designed to nest within each other in the narrow configuration, with the first side panel, second side panel, top panel, and bottom panel arranged to minimize overall dimensions, enabling easy insertion into the support channel before expansion

Inventive Principle:

Principle #7Nested doll (Nesting)

Data Source

PatentUS12132440B2Expandable splice for a solar power system

Publication Date: 2024.10.29 NEXTPOWER LLC

AI summary

The present disclosure describes an expandable splice configured for reinforcing a tube of a solar owner system, the splice including a top panel, a bottom panel, a first side panel, a second side panel, and at least one beveled corner panel, wherein the first and second side panels are connected to the top and bottom panels either directly or by the at least one beveled corner panel to form a channel therebetween.