Nested PV Module Mounting Assembly for Deflection Control
Solution Overview
Problem
Existing solar panel mounting assemblies are cumbersome, costly, and lack sufficient stiffness to prevent significant deflection of larger PV modules under mechanical load, which can lead to failure as the glass surface of the module may move below the bottom of the module frame.
Innovation Solution
A mounting assembly comprising a reinforcement channel that nests around a hat-shaped channel, which in turn nests around a load distributing channel, providing additional stiffness through a fastener system that connects to both the top and bottom of the PV module frame, reducing deflection by acting like a fixed connection rather than a simply supported one.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If PV module size is increased to achieve economies of scale, then cost per unit of energy is reduced, but deflection under mechanical loading increases significantly
Solution Approach 1:
The mounting assembly uses nested channel structures where a first hat-shaped channel nests around a second hat-shaped channel, which in turn nests around a load distributing channel. This nested configuration provides multiple levels of structural support and stiffness to handle the increased deflection of larger PV modules while maintaining cost-effectiveness through standardized component design
2Ease of operation
If mounting assembly uses traditional U-bolt and nuts configuration, then installation is simple, but the assembly is cumbersome and costly for larger modules
Solution Approach 1:
The mounting assembly is segmented into distinct functional components: a mounting base for attachment to the PV module, nested hat-shaped channels for providing structural stiffness at different levels, and a fastening mechanism. This segmentation allows each component to be optimized for its specific function while maintaining overall simplicity of installation
Solution Approach 2:
The mounting assembly design incorporates multi-functional elements where the nested channels serve both as structural stiffeners and as attachment points for fasteners. The hat-shaped channels provide both mechanical support and a standardized interface for securing the assembly, reducing the need for additional specialized components
3Stability of the object's composition
If mounting assembly provides sufficient stiffness to prevent deflection, then module stability is improved, but the assembly becomes more costly and cumbersome
Solution Approach 1:
The nested channel configuration provides progressive stiffness where each nested level contributes to the overall structural rigidity. The first hat-shaped channel nested around the second hat-shaped channel, which surrounds the load distributing channel, creates a multi-layered stiffening effect that prevents excessive deflection of larger modules without requiring an overly complex single-component solution
Data Source
AI summary
A mounting assembly comprises a reinforcement channel configured to nest around a first base of a first hat-shaped channel wherein the first hat-shaped channel is configured to nest around a second base of a second hat-shaped channel and the second hat-shaped channel is configured to nest around a load distributing channel. The mounting base, the reinforcement channel, the first hat-shaped channel, the second hat-shaped channel and the load distributing channel are configured to be removable with respect to a fastener along the fastener axis. The fastener is received through coaxial apertures located within the mounting base, the reinforcement channel, the first hat-shaped channel, the second hat-shaped channel and the load distributing channel. The channels are of a certain length that is sufficient to add stiffness to an object being supported by the mounting assembly.