Mounting Bracket Extension Panel for Single-Bolt PV Module Assembly
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Solution Overview
Problem
Existing solar mounting systems for photovoltaic (PV) modules are heavy, complex, and costly due to the need for large, heavy components to support PV arrays and withstand natural forces, requiring significant material and skilled labor for installation, and are not adaptable to standard, custom, or unframed modules.
Innovation Solution
A mounting bracket assembly with a flexible body and extension panels that securely attach PV modules to a torsion beam using a single bolt, allowing for efficient use of structural material, easier installation, and compatibility with various module types by extending the contact point and surface area, thereby reducing material stress and installation time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If large, heavy components are used to support PV modules and withstand natural forces, then the structural strength and stability are improved, but the overall weight and material usage increase significantly
Solution Approach 1:
The mounting system is divided into separate functional components: a clamp assembly for securing the PV module, a bracket for mounting to the support structure, and an extension panel for adjusting reach and positioning. This segmentation allows each component to be optimized independently, using material only where structurally necessary rather than requiring a single large heavy component.
Solution Approach 2:
The clamp assembly features localized reinforcement at critical stress points (such as the clamping arms and mounting holes) while using thinner gauge material in non-critical areas. The extension panel uses adequate thickness only at the mounting interface and tapers or reduces material toward the free end, placing structural material only where it is needed to resist applied loads.
2Adaptability or versatility
If complex assemblies with multiple components are used to accommodate different PV module types, then the adaptability is improved, but the device complexity and installation difficulty increase
Solution Approach 1:
The clamp assembly is designed as a universal mounting mechanism that can secure various PV module types (standard framed, custom framed, and unframed modules) through a single clamping action. The adjustable clamp width and versatile clamping interface allow one component design to serve multiple functions across different module configurations, eliminating the need for multiple specialized clamp designs.
Solution Approach 2:
The clamp assembly incorporates movable or adjustable elements (such as adjustable clamp positions, rotatable mounting brackets, or flexible extension panels) that can be configured during installation to match different PV module dimensions and orientations. This dynamic adjustability allows a single base design to adapt to various module types without requiring multiple fixed designs.
3Reliability
If multiple bolts and fasteners are used to secure the mounting bracket, then the connection reliability is improved, but the installation time and labor requirements increase
Solution Approach 1:
The mounting bracket and extension panel are designed to be secured together using a single bolt or fastener that simultaneously attaches both components and provides structural continuity. This merging of attachment functions into a single fastening operation maintains connection reliability while dramatically reducing the number of fastening steps required during installation.
Solution Approach 2:
The extension panel and clamp assembly are pre-configured or pre-assembled as integrated units with built-in alignment features, pre-drilled holes, and self-aligning interfaces. This preliminary preparation ensures that when installation occurs, the components naturally align and can be secured with minimal adjustment and a single fastening operation, reducing on-site installation time while maintaining secure connections.
Data Source
AI summary
An extension panel may include a mating surface shaped to interface with a back surface of a clamp that includes a mounting hole corresponding to a bolt slot in the back surface of the clamp to accommodate a single bolt passing through the extension panel and the clamp. The extension panel may also include a pair of flanges projecting outward from the mating surface and positioned to be on either side of the clamp. The extension panel may also include a flat top surface generally parallel and aligned linearly with another flat top surface of a flexible member. The extension flat top surface may be sized to be approximately a same width as the flexible member at a first end of the extension flat top surface proximate the mating surface and may flare out as the extension flat top surface extends away from the flexible member.