Photovoltaic module and module arrays
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional photovoltaic module installation techniques for commercial rooftops are time-consuming, costly, and require extensive upfront planning due to the need for numerous auxiliary components and complex logistics, especially when aiming for non-penetrating, tilted installations, which can be prone to errors and labor-intensive.
Innovation Solution
A photovoltaic module system featuring a frame that encases the PV laminate to form a unitary structure, allowing for non-penetrating installation at a tilted angle without requiring additional rooftop penetration, with a simplified manufacturing process and minimal additional parts, enabling easy assembly and orientation during installation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If conventional non-penetrating PV module installation techniques are used with multiple auxiliary components, then the PV modules can be tilted relative to the rooftop, but the installation process becomes time-consuming and requires extensive upfront planning
Solution Approach 1:
The patent combines the PV module frame, mounting arms, and tilt adjustment mechanisms into a single integrated unitary structure. The frame members are formed as one piece with integrated arms that directly engage the rooftop surface, eliminating the need for separate auxiliary components like individual mounting brackets, bolts, and adjustment mechanisms. This merging of functions into a single component dramatically reduces installation time and eliminates the need for extensive upfront planning of multiple parts.
Solution Approach 2:
The unitary frame structure serves multiple functions simultaneously: it provides structural support for the PV laminate, creates the tilted orientation angle, interfaces with the rooftop surface, and enables interconnection between adjacent modules. The single frame component performs what previously required multiple specialized components, reducing both installation complexity and time requirements while maintaining the desired tilted orientation.
2Shape
If conventional non-penetrating PV module installation uses multiple separate auxiliary components, then tilted installation is achieved, but the number of parts and logistical complexity increases
Solution Approach 1:
The patent consolidates multiple auxiliary components (mounting brackets, arms, fasteners, adjustment mechanisms) into a single unitary frame structure. The frame is formed as one integrated piece that incorporates all mounting functions, eliminating the need to manage, track, and install multiple separate components. This single-component approach maintains the tilted orientation capability while dramatically reducing device complexity and part count.
3Strength
If PV modules are physically attached to the rooftop via bolts through the rooftop, then rigid mounting is achieved, but the rooftop is permanently damaged and water damage risk increases
Solution Approach 1:
The patent extracts the penetrating mounting method and replaces it with a non-penetrating alternative. The unitary frame structure achieves rigid mounting through friction engagement and mechanical interlocking with the rooftop surface without requiring holes or penetrations. The arms of the frame rest against and engage the rooftop surface, providing stable, rigid support while leaving the rooftop material intact and preventing water infiltration pathways.
4Object-affected harmful factors
If PV modules are interconnected via separate auxiliary components, then non-penetrating installation is achieved, but shipping and handling costs increase due to numerous parts
Solution Approach 1:
The patent merges all auxiliary mounting components into the single unitary frame structure, which is factory-assembled and tested as one complete unit. This eliminates the need to ship and handle multiple separate auxiliary components individually. The frame arrives at the installation site as a single pre-assembled component ready for immediate installation, dramatically reducing shipping volume, handling requirements, and associated costs while maintaining the non-penetrating installation capability.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution simplifies the installation process, reduces labor and upfront planning, minimizes shipping and handling costs, and ensures efficient energy collection by allowing for tilted PV module arrays with reduced logistical complexity and material requirements.
Implementation Method 1
solar photovoltaic systems (or simply 'photovoltaic systems') employ solar panels made of silicon or other materials (e.g., III-V cells such as GaAs) to convert sunlight into electricity
Data Source
Figure 1A
Figure 1B
Figure 2
AI summary
A photovoltaic (PV) module including a PV device and a frame. The PV device has a PV laminate defining a perimeter and a major plane. The frame is assembled to and encases the laminate perimeter, and includes leading, trailing, and side frame members, and an arm that forms a support face opposite the laminate. The support face is adapted for placement against a horizontal installation surface, to support and orient the laminate in a non-parallel or tilted arrangement. Upon final assembly, the laminate and the frame combine to define a unitary structure. The frame can orient the laminate at an angle in the range of 3°-7° from horizontal, and can be entirely formed of a polymeric material. Optionally, the arm incorporates integral feature(s) that facilitate interconnection with corresponding features of a second, identically formed PV module.