Method for installing solar cell module
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Solution Overview
Problem
Conventional methods for installing solar cell modules on roofs are risky due to the weight of the module and the need for workers to climb, which can damage the roof and pose a fall hazard, and require skilled labor for high-location installation.
Innovation Solution
A method using a solar cell module with a resin frame installed on a rack with opposed grooves, allowing the module to be fitted and fixed without direct roof contact, using rails and locking members to secure it, enabling easier and safer installation without climbing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional metal frames and heavy racks are used, then structural strength is improved, but roof load increases and installation becomes more dangerous
Solution Approach 1:
The patent changes the material parameter of the frame from metal to resin, fundamentally altering the weight characteristic while maintaining structural functionality. This parameter change enables the frame to be lightweight enough for safe installation without requiring workers to climb onto the roof, while still providing sufficient strength to support the solar cell module.
Solution Approach 2:
The patent employs composite material construction for both the frame and rack, using resin-based materials that combine adequate mechanical strength with reduced weight. The rack itself is constructed as a lightweight structure that provides necessary support without imposing excessive load on the roof, resolving the contradiction between strength requirements and weight constraints.
2Ease of manufacture
If workers climb onto the roof for installation, then module installation is completed, but fall risk and roof damage risk increase
Solution Approach 1:
The patent applies the equipotentiality principle by enabling installation to be performed from ground level rather than requiring elevation to the roof surface. The lightweight rack system is designed to be installable without workers climbing onto the roof, eliminating the fall hazard and roof damage risk associated with high-location work while still achieving complete module installation.
3Reliability
If lightweight resin frames are used, then installation safety is improved, but structural strength may be reduced
Solution Approach 1:
The patent successfully changes the material parameter from metal to resin while maintaining the strength parameter within acceptable ranges. The resin frame is engineered to provide sufficient structural strength for supporting solar cell modules, demonstrating that material parameter changes can be made without compromising essential strength requirements when the new material is properly selected and designed.
4Reliability
If conventional installation methods are used, then secure fixation is achieved, but skilled labor is required and installation complexity increases
Solution Approach 1:
The patent applies self-service principles through the groove-retention mechanism where the rack structure itself provides the fixation function. The grooves in the rack engage with the resin frame, creating a self-retaining system that reduces the need for complex additional fixation components and skilled installation techniques, while still achieving secure fixation of the solar cell module.
Data Source
AI summary
A method is disclosed for installing a solar cell module, which enables easy installation of a solar cell module on a rack, and also enables a worker to install a solar cell module without climbing on the roof. A solar cell module is installed on a rack mounted on a roof. The solar cell module includes a frame formed of a material containing a resin. The rack includes multiple rails each having a groove, and the grooves of a pair of the rails are disposed to be opposed to each other. The method of this invention comprises the steps of fitting the frame of the solar cell module into the groove such that the solar cell module is retained by the pair of the rails, and fixing the solar cell module to the pair of the rails to prevent the solar cell module from falling out of the grooves.