Frameless Solar Module Clamps for Cost-Effective Assembly
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Solution Overview
Problem
The high cost and aesthetic drawbacks of traditional photovoltaic arrays with metallic frames hinder the widespread adoption of solar energy, as these frames contribute significantly to the manufacturing and installation costs, and are not aesthetically pleasing.
Innovation Solution
The development of clamps specifically designed for frameless photovoltaic modules, which include a clamp cover and grip that form pockets to securely attach frameless PV modules to rail systems using a fastener, allowing for secure and aesthetic installation without the need for metal framing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If metallic frames are used to support photovoltaic modules, then structural strength and stability are improved, but manufacturing costs and aesthetic appearance deteriorate
Solution Approach 1:
The patent removes the traditional metallic frame from the photovoltaic module assembly, extracting only the essential support function and replacing it with a rail system and specialized clamps. This eliminates the costly and aesthetically problematic metal framing while maintaining structural integrity through the rail-clamp-module assembly.
Solution Approach 2:
The support system is segmented into separate functional components: rails provide the primary support structure, while specialized clamps provide the module-to-rail connection. This segmentation allows each component to be optimized independently, reducing overall cost and improving aesthetics compared to a monolithic metal frame approach.
2Stability of the object's composition
If metallic frames are used to support photovoltaic modules, then structural stability is improved, but aesthetic appearance deteriorates
Solution Approach 1:
The metallic frame is extracted from the assembly, removing the aesthetic drawback while preserving structural stability through the rail and clamp system. The frameless design allows for cleaner, more visually appealing installations while the engineered clamp provides adequate mechanical stability.
Solution Approach 2:
The clamp is designed with localized structural features (reinforced walls, proper thickness distribution) that provide structural stability only where needed for module support, while the overall frameless design maintains aesthetic quality. This localized approach to strength allows aesthetic compromise only in the minimal necessary areas.
3Ease of manufacture
If frameless photovoltaic modules are used, then manufacturing cost is reduced, but secure attachment to rail system becomes more difficult
Solution Approach 1:
The specialized clamp acts as an intermediary component between the frameless photovoltaic module and the rail system. It provides the necessary mechanical interface and secure attachment mechanism that would otherwise be provided by a metal frame, enabling reliable installation of frameless modules without compromising attachment security.
4Shape
If traditional metal framing is eliminated, then aesthetic appearance is improved, but device complexity increases due to specialized clamp design
Solution Approach 1:
The clamp integrates multiple functions into a single component: it provides structural support, secures the module to the rail, and maintains proper positioning. By merging these functions into one element, the overall device complexity is reduced compared to having separate components for each function, even though the clamp itself has a specialized design.
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
The clamps enable cost-effective and aesthetically pleasing assembly of photovoltaic arrays by eliminating the need for metal framing, reducing manufacturing costs and enhancing the visual appeal of solar installations while ensuring secure attachment of frameless PV modules to rail systems.
Implementation Method 1
the first clamp arm engages the upper wall of the first side wall of the clamp grip such that the upper wall of the first side wall of the clamp grip bends at the bending point away from the clamp grip channel to form a pocket
Data Source
AI summary
The present disclosure provides clamps used to assemble photovoltaic (PV) arrays with frameless PV modules. The clamp includes a clamp cover configured to fit within a clamp grip such that when the clamp cover is fitted to the clamp grip pockets are formed to receive portions of PV modules. A base of the clamp cover may include one or more legs that act as a stop to prevent over tightening the clamp.