Photovoltaic Module Mounting Assembly with Tool-Free Toe-Slot Coupling
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Solution Overview
Problem
Existing PV module mounting systems require tools for installation, are prone to loosening due to thermal expansion, and suffer from material wear in the grounding process, leading to increased costs and reduced system reliability.
Innovation Solution
The development of PV module couplings with a toe portion and retainer portion that allow for tool-free assembly, accommodate thermal expansion, and provide a secure grounding connection through a mounting chassis with a grounding plate and locking mechanism, ensuring stability and resistance to weathering.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If traditional mounting components are used to attach the module frame to the module chassis, then the PV panels can be mounted on the support surface, but tools are required for installation and the components are prone to loosening due to thermal expansion
Solution Approach 1:
The mounting component is designed to perform its own installation without external tools. The L-shaped configuration with perpendicular first and second portions allows the component to be inserted and secured through a snap-fit or friction-fit mechanism, where the component itself completes the mounting operation by being placed into the receiving structure on the module chassis.
Solution Approach 2:
The mounting component incorporates features that accommodate thermal expansion and contraction. The L-shaped geometry with specific dimensional relationships between the first and second portions allows for movement and adjustment in response to temperature changes, preventing loosening while maintaining a secure attachment.
2Reliability
If traditional grounding methods are used, then electrical grounding can be established, but material wear occurs during the grounding process
Solution Approach 1:
The mounting component integrates multiple functions into a single structure. The same L-shaped component that provides mechanical attachment also serves as the grounding path. By combining the mounting function and grounding function into one component, the invention eliminates the need for separate grounding contacts that would otherwise experience material wear through repeated contact and adjustment.
3Reliability
If multiple separate components are used for mounting and grounding, then functional requirements can be met, but installation time and cost increase
Solution Approach 1:
The invention consolidates multiple functions into a single integrated mounting component. The L-shaped structure combines the mechanical mounting function (attaching the frame to the chassis) with the electrical grounding function (providing a conductive path to ground). This integration reduces the number of parts that need to be handled, positioned, and secured during installation, thereby reducing installation time and cost while maintaining all required functionalities.
Data Source
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AI summary
Mounting components of photovoltaic (PV) modules and PV module assemblies are described, including PV module couplings and PV module mounting chassis. In an example, a PV module includes a PV module coupling having a toe portion extending from a PV module frame, and a PV module mounting chassis includes a toe slot to receive the toe. The toe and toe slot construction allows for the PV module frame to be assembled to the PV module mounting chassis without using tools, and thus, permits a PV module assembly to be quickly constructed during installation of a PV module system. Furthermore, the toe and toe slot construction accommodates thermal expansion and other environmental loads seen after installation, while providing a grounding connection for the PV module assembly.