Folding PV Panel Mounting Without Roof Racking
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Solution Overview
Problem
The high costs and complexities associated with the installation of conventional photovoltaic (PV) modules, including expensive logistics, shipping, and labor costs, due to their large and heavy nature, as well as the time-consuming process of removing or reducing racking systems, necessitate a more efficient and cost-effective mounting solution for PV cells.
Innovation Solution
The development of folding PV panels with interconnected subpanels via flexible regions, such as hinges, allowing for easy stacking and transportation, and an integrated mounting system that eliminates the need for additional hardware and minimizes installation training, using a frameless design with integrated flashing and fasteners for direct roof attachment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If conventional PV modules are used, then photovoltaic energy conversion is achieved, but shipping and handling costs increase due to large and heavy size
Solution Approach 1:
The PV module is divided into multiple lightweight subpanels that can be separately manufactured and transported. Each subpanel contains a portion of the PV cells and can be handled more easily than a complete conventional module, reducing shipping costs and handling difficulties while maintaining the overall photovoltaic functionality when assembled together.
Solution Approach 2:
The patent employs thin-film PV cells and flexible mounting structures that enable lightweight construction. The flexible regions and thin-film technology allow the PV system to achieve energy conversion functionality with significantly reduced weight compared to conventional rigid modules, lowering transportation and installation costs.
2Ease of operation
If conventional PV modules with racking systems are installed, then mounting is achieved, but installation time and complexity increase
Solution Approach 1:
The mounting function is merged directly into the subpanel structure through integrated mounting features and flexible regions. This eliminates the need for separate racking systems and complex assembly procedures, allowing installers to mount PV panels directly to surfaces using the built-in mounting features, significantly reducing installation time and complexity.
Solution Approach 2:
The subpanels are designed with self-aligning and self-mounting capabilities through their flexible regions and integrated mounting features. The system allows for tool-free or minimal-tool installation where the flexible regions automatically conform to the mounting surface, reducing the skill level and time required for installation.
3Device complexity
If frameless design with integrated mounting is used, then installation complexity is reduced, but structural strength must be maintained
Solution Approach 1:
The flexible regions serve dual purposes: they simplify the mounting process by eliminating complex racking systems while simultaneously providing structural reinforcement to the subpanels. The flexibility allows the thin-film structure to conform to various surfaces and absorb stress, maintaining structural integrity without requiring additional framing.
Solution Approach 2:
The subpanels utilize composite construction combining thin-film PV cells with reinforced flexible substrates and integrated mounting features. This composite structure achieves the necessary structural strength to support the PV system while maintaining the frameless design, balancing simplicity with mechanical robustness.
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 shipping and handling costs, simplifies the installation process, and provides a sleek, aesthetically pleasing appearance while maintaining efficiency and ease of use, enabling rapid and cost-effective mounting of PV panels on surfaces like roofs with minimal training.
Implementation Method 1
a hinge assembly rotationally coupling the first subpanel and the second subpanel to allow an angle between the first lateral plane and the second lateral plane to change
Implementation Method 2
Photovoltaic (PV) cells, commonly known as solar cells, are well known devices for converting solar radiation into electrical energy
Data Source
AI summary
Modular photovoltaic (PV) panel, system, and method of mounting. The system including a mounting flashing configured to mounted to a mounting surface and a folding PV panel. The folding PV panel including: a first subpanel including first PV cells, wherein the first subpanel extends along a first lateral plane and comprises a plurality of mounting hooks extending laterally from and affixed to a backside of the first subpanel, the mounting hooks configured to couple to the mounting flashing; a second subpanel including second PV cells, wherein the second subpanel extends along a second lateral plane, wherein the second subpanel comprises a front edge support configured to hold a front edge of the second subpanel away from the mounting surface; and a hinge assembly rotationally coupling the first subpanel and the second subpanel to allow an angle between the first lateral plane and the second lateral plane to change.