Array including frameless solar modules
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Solar modules experience stress and structural issues due to movement and environmental forces like wind, snow, and ice when mounted on surfaces, and existing solutions require complex framing and electrical bonding, which increase costs and reduce energy generation.
Innovation Solution
A frameless solar array system with molded plastic pylons and keys that allow modules to move in one plane while being secured in another, using a locking mechanism that allows for tool-less installation and reduces the need for electrical bonding, incorporating clips for assembly and stacking, and wire receivers for efficient wire management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If solar modules are rigidly secured to the support structure, then structural stability is improved, but thermal expansion stress and module damage increase
Solution Approach 1:
The patent employs a dynamic mounting system where the solar module can move relative to the support structure through a channel mechanism. The module is constrained in the vertical direction (perpendicular to the surface) by the locking mechanism while being allowed to move horizontally (parallel to the surface) to accommodate thermal expansion. This dynamic capability resolves the contradiction by providing stability where needed while permitting movement to relieve stress.
2Strength
If traditional framing is used to secure solar modules, then structural support is improved, but energy generation and installation simplicity deteriorate
Solution Approach 1:
The patent extracts and eliminates the traditional aluminum frame from the solar module assembly. Instead of using a frame that surrounds and constrains the module, the invention uses a frameless design where the module is directly mounted to the support structure through clips and a locking mechanism. This removal of the frame eliminates the obstruction to light capture while maintaining structural support, thereby resolving the contradiction between structural strength and energy generation efficiency.
3Reliability
If complex electrical bonding is required for module assembly, then electrical connectivity is improved, but installation time and cost increase
Solution Approach 1:
The patent merges the mechanical support function and electrical connectivity function into a single integrated component. The support structure includes built-in conductive elements that provide both mechanical support and electrical bonding simultaneously. This eliminates the need for separate electrical bonding steps, reducing installation time and complexity while maintaining reliable electrical connectivity. The locking mechanism that secures the module mechanically also ensures electrical contact.
Data Source
AI summary
A solar array is mounted on a surface of a structure, the surface being generally planar. The solar array comprises a solar module and a support that supports the solar module a distance above the surface. The support defines a channel to receive the solar module. A locking mechanism engages the support to secure the solar module to the support, wherein the solar module extends between the support and the locking mechanism and into the channel such that the solar module is allowed to move relative to the support in a first plane generally parallel to the surface when the solar module is secured to the support. The locking mechanism and the support inhibit movement of the solar module in a second plane generally perpendicular to the surface when the solar module is secured to the support.