Hidden End Clamp for Concealed Solar Module Mounting
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Solution Overview
Problem
Current solar mounting solutions using rails and clamps detract from the aesthetic appearance due to visible clamps at the end of solar module rows, as they do not provide a clean and concealed attachment method.
Innovation Solution
A clamp assembly comprising a Clamp Block, Clamp Arm, Grip Body, Fastener, and Pull-Tab, which allows for secure attachment to a rail and solar module frame with a hinge mechanism that enables rotation and lateral movement, utilizing grooves and protrusions for secure engagement and potential electrical bonding, while the Pull-Tab and Catches ensure stability and concealment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If traditional clamps are used to secure solar modules to rails, then the mounting function is achieved, but the aesthetic appearance is diminished due to visible clamps at the end of solar module rows
Solution Approach 1:
The visible portion of the clamp is extracted and removed from the system. The clamp assembly is designed so that the clamp block and clamp arm are positioned entirely behind the solar module frame, with only the rail visible from the front. This extraction of the visible clamp component directly resolves the aesthetic contradiction by eliminating the unwanted visual element while preserving the mounting function.
Solution Approach 2:
The clamp assembly is nested within the structure formed by the solar module frame and rail. The clamp block nests between the rail and the solar module frame, while the clamp arm nests behind the frame. This nesting arrangement hides the clamp components within the existing structural boundaries, achieving aesthetic concealment without compromising the secure mounting capability.
2Shape
If the clamp assembly is concealed behind the solar module frame, then aesthetic appearance is improved, but the complexity of the attachment mechanism increases
Solution Approach 1:
The clamp assembly is segmented into distinct functional components: the clamp block for engaging the rail, the clamp arm for securing the solar module frame, the hinge for enabling rotation, and the fastener for locking the mechanism. This segmentation allows each component to be optimized for its specific function while working together as a coordinated system, managing the overall complexity through modular design.
Solution Approach 2:
The hinge mechanism introduces dynamic capability to the otherwise static clamp structure. The hinge enables the clamp arm to rotate from an open position to a clamping position, allowing the assembly to adapt to the solar module frame during installation. This dynamic element simplifies the installation process while maintaining the concealed aesthetic appearance in the final installed state.
3Ease of operation
If the clamp block and clamp arm are rotatably coupled via a hinge, then ease of installation is improved, but the device complexity increases
Solution Approach 1:
The hinge mechanism merges the functions of rotation and structural support into a single integrated component. The hinge pin serves both as the rotation axis and as a structural element that connects the clamp block and clamp arm. This merging reduces the number of separate components needed compared to using separate hinges and connection elements, thereby managing complexity while providing the desired rotational capability for easy installation.
Data Source
AI summary
A clamp particularly designed for use on the end of a solar module mounting rail, includes two hinged parts that can be adjusted by a fastener to clamp a solar module to the rail. A pull-tab with toothed catches helps to position the clamp during installation, and also prevents the clamp from sliding too far into the rail, while a grip body increases friction and electrical contact between the solar module and the clamp.