Interlock Support Coupling for PV Module Mounting Conflict Resolution

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Current photovoltaic (PV) mounting systems face conflicts between mechanical linkages and supporting members due to variable PV module arrays and roof structures, leading to increased complexity, cost, and installation time, as well as susceptibility to component failure and material inefficiencies.

Innovation Solution

An interlock support coupling system with a bracket and support coupling member that allows for adjustable alignment and locking, providing an electrically grounded connection, and a leveling foot assembly that reduces part count and material usage, enabling flexible installation and reduced torque on components.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If specially-designed supporting feet with additional length are used to resolve conflicts between mechanical links and supporting members, then the conflicts are resolved, but the torque magnitude increases and component susceptibility to failure increases

Engineering Contradiction:

Improveability to resolve conflicts between mechanical links and supporting membersVSAvoidcomponent susceptibility to failure

Core Design Contradiction:

Adaptability or versatilityVSReliability

Solution Approach 1:

The supporting foot is divided into two distinct components: a mounting portion that attaches to the roof structure and a coupling portion that connects to the bracket. This segmentation allows each component to be optimized independently, with the coupling portion being shorter and stronger to reduce torque while the mounting portion provides the necessary reach to rafters.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

A bracket is introduced as an intermediary component between the supporting foot and the PV modules. The bracket includes a slot that receives the coupling portion, creating a standardized interface that resolves location conflicts without requiring extended foot length, thereby reducing torque on the connection components.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Adaptability or versatility

If specially-designed supporting feet with additional length are used to resolve conflicts, then the conflicts are resolved, but material costs and part cost increase

Engineering Contradiction:

Improveability to resolve conflicts between mechanical links and supporting membersVSAvoidmaterial usage

Core Design Contradiction:

Adaptability or versatilityVSQuantity of substance

Solution Approach 1:

The supporting foot is segmented into mounting and coupling portions, allowing the coupling portion to be minimized in length while the mounting portion provides necessary reach. This reduces overall material usage compared to a single extended-foot design.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The bracket with slot and coupling portion creates a universal interface that can accommodate various mounting scenarios without requiring custom-length supporting feet for each situation, reducing material variety and inventory requirements.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Adaptability or versatility

If hybrid interlocks are used to resolve conflicts between interlocks and leveling feet, then the conflicts are resolved, but part complexity and part count increase

Engineering Contradiction:

Improveability to resolve conflicts between interlocks and leveling feetVSAvoidassembly complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The system separates the supporting foot function from the interlock function, with each component remaining simple and specialized. The bracket provides a standardized slot interface that simplifies the connection without requiring complex hybrid assemblies.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The bracket with slot serves as a universal interface that works with both interlocks and supporting feet, eliminating the need for specialized hybrid interlocks and reducing overall system complexity.

Inventive Principle:

Principle #6Universality (Multi-functionality)

4Adaptability or versatility

If hybrid interlocks are used to resolve conflicts, then the conflicts are resolved, but installation time and cost increase

Engineering Contradiction:

Improveability to resolve conflicts between interlocks and leveling feetVSAvoidinstallation time

Core Design Contradiction:

Adaptability or versatilityVSLoss of time

Solution Approach 1:

The bracket with slot and coupling portion are pre-configured to work together, allowing installers to simply connect components rather than assemble complex hybrid interlocks during installation, reducing installation time.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The segmented design allows components to be pre-assembled and tested separately, then quickly installed on-site without requiring complex field assembly procedures.

Inventive Principle:

Principle #1Segmentation

Data Source

PatentUS10340836B2Interlock system for mounting and joining photovoltaic modules

Publication Date: 2019.07.02 TESLA INC

AI summary

Assemblies and couplings for mounting PV modules are provided. An assembly is provided to avoid conflicts between linkages used to adjoin adjacent PV modules and leveling feet used to mount the PV modules to supporting structure. Specifically, an interlock support coupling is provided that may include a shaft with a locking portion disposed at the end that interfaces with an interlock bracket used to couple adjacent PV modules and a housing with an opening for receiving a connection with a supporting foot. An interlock bracket may be provided with a slot for receiving an interlock support coupling.