Gravel-Based Solar Module Mounting System
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Solution Overview
Problem
Existing solar module mounting methods are costly and require extensive assembly, lead to mutual shading under oblique solar radiation, and result in increased maintenance due to vegetation growth, while thin-film modules are prone to wind suction and heat dissipation inefficiencies.
Innovation Solution
A method involving the placement of solar modules on a leveled surface covered with a plastic film and multiple layers of gravel, with an inclined top for rainwater runoff and self-curing foam for stability, preventing vegetation and enhancing heat dissipation, and allowing for easy removal and reuse of materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If solar modules are mounted on inclined frames or stands, then the electrical power generated is increased by aligning the light-sensitive surface perpendicular to incoming sunlight, but the material costs and installation effort increase considerably
Solution Approach 1:
The patent extracts the essential function of module support from complex framed structures and implements it through a simplified gravel-based mounting system. The gravel layer directly supports the modules on the ground surface, eliminating the need for elaborate frames, stands, and anchoring systems while maintaining proper module orientation and stability.
Solution Approach 2:
The patent employs inexpensive gravel as the primary mounting medium, replacing costly metallic frames and structural components. The gravel layer serves as both the mounting base and drainage system, significantly reducing material costs and simplifying installation while providing sufficient support for the solar modules.
2Power
If solar modules are arranged in parallel rows at larger intervals, then mutual shading is avoided, but the occupied ground area increases disadvantageously
Solution Approach 1:
The patent creates localized drainage channels and gravel configurations directly beneath and between the modules to manage shading effects. By optimizing the local gravel arrangement and creating targeted drainage paths, the system allows modules to be positioned closer together without excessive mutual shading, as the improved drainage prevents water accumulation that would exacerbate shading problems.
Solution Approach 2:
The patent addresses the ground area issue by introducing vertical and subsurface dimensions through elevated module positioning on gravel and underground drainage channels. This three-dimensional approach allows for denser horizontal module arrangement while maintaining proper spacing for light exposure, as the drainage functionality is moved to the vertical subsurface dimension rather than requiring excessive horizontal separation.
3Device complexity
If thin-film solar modules are mounted directly on the ground, then installation costs are reduced, but the modules are prone to wind suction and heat dissipation inefficiencies
Solution Approach 1:
The patent uses the gravel layer as a counterbalancing medium that provides both mechanical support and wind resistance for the thin-film modules. The gravel's weight and friction create a stabilizing effect that counteracts wind suction forces, allowing direct ground mounting without additional anchoring systems while maintaining module stability and reliability.
Solution Approach 2:
The gravel layer serves as an intermediary between the ground and the thin-film modules, providing thermal management and mechanical support. The gravel facilitates heat dissipation from the module undersides and creates a stable mounting surface that prevents direct contact with the ground while maintaining cost-effective installation simplicity.
4Reliability
If solar modules are mounted on frames, then stability against wind suction is improved, but grass and plant growth develops under the frames over time requiring regular removal
Solution Approach 1:
The gravel-based mounting system is self-service regarding vegetation control, as the gravel layer itself prevents grass and plant growth by blocking sunlight and physical penetration. The system automatically maintains itself without requiring manual vegetation removal, while still providing adequate stability against wind suction through the gravel's friction and weight.
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 method reduces costs and maintenance by stabilizing modules against wind and heat, preventing shading, and facilitating easy removal and reuse of materials, while improving the efficiency of thin-film solar modules.
Implementation Method 1
a plastic sheet is laid on the level surface... which is used in agriculture and horticulture to prevent the growth of plants growing underground
Implementation Method 2
the modules are cooled from below by the gravel, and the heat generated by the incident sunlight is effectively dissipated
Implementation Method 3
self-curing foam for stability, preventing vegetation and enhancing heat dissipation
Implementation Method 4
self-curing foam for stability
Implementation Method 5
its surface is leveled and smoothed using a suitable tool... to create a sloping surface for the solar modules. This slope facilitates the runoff of rainwater
Data Source
Figure 1
Figure 2
AI summary
A method for mounting photovoltaic solar modules (2), in particular thin-layer solar modules, on a base (4) is distinguished by the fact that, in a first method step, a first plastic film (6) is applied to the upper side (5) of the base (4), then a first layer (8) of gravel (8a) is arranged on the plastic film (6) and subsequently the solar modules (2) are placed on the first layer (8) of gravel (8a). The invention further relates to an arrangement (1) for mounting solar modules (2) on a substantially planar base (4).