Photovoltaic module mounting system
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Solution Overview
Problem
Existing photovoltaic module mounting systems are inefficient and aesthetically unpleasing due to the need for numerous fastening elements and adjustments, which increase installation complexity and cost, while exposing mounting hardware and rails, compromising the appearance of installations.
Innovation Solution
A photovoltaic mounting system featuring a mounting frame offset from the module's perimeter edges with spaced mounting rails and retainers that securely engage the frame, allowing for adjustable and efficient module placement without visible fastening elements, enabling easy alignment and leveling of modules.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional mounting systems use numerous fastening elements and threaded bolts to secure PV modules, then the modules can be securely attached to structures, but the installation complexity and time increase significantly
Solution Approach 1:
The mounting frame integrates multiple fastening functions into a single unified structure that attaches to the PV module edges. Instead of using separate threaded bolts, nuts, and clamps at multiple locations, the mounting frame combines these functions into one component that secures the module to the rail system, thereby reducing installation complexity while maintaining secure attachment.
Solution Approach 2:
The mounting frame serves multiple functions simultaneously: it provides structural support for the PV module, enables attachment to mounting rails, allows for positioning adjustments, and conceals mounting hardware. This multi-functional design eliminates the need for separate components for each function, reducing both the number of parts and installation steps.
2Manufacturing precision
If traditional mounting systems require adjustment of numerous fastening elements, then proper module positioning can be achieved, but installation time increases
Solution Approach 1:
The mounting frame is pre-configured with integrated fastening mechanisms and positioning features during manufacturing. The retainers and mounting projections are pre-positioned to work together with the rail system, eliminating the need for field adjustments of multiple fastening elements. This preliminary preparation maintains precise module positioning while significantly reducing installation time.
3Reliability
If mounting hardware engages the edge of the module, then secure attachment is achieved, but the module edges cannot be placed in close proximity and aesthetics are compromised
Solution Approach 1:
The mounting frame and retainers are designed to nest within or alongside the PV module edges and rail structure. The mounting projections engage with the frame in a nested configuration that allows module edges to be placed in close proximity while maintaining secure attachment. This nesting arrangement conceals the mounting hardware, improving aesthetic appearance without compromising attachment security.
4Ease of manufacture
If traditional systems expose mounting hardware and rails, then installation is simplified, but the aesthetic appeal of the installation is negatively affected
Solution Approach 1:
The mounting hardware (bolts, nuts, clamps) is extracted from visible positions and integrated into the mounting frame structure that attaches to the PV module edges. The frame conceals these fastening elements, removing them from view while maintaining their functional role in securing the module to the rails, thus preserving both installation simplicity and aesthetic appeal.
Data Source
AI summary
A photovoltaic mounting system including a photovoltaic module having a panel having an upper surface including a plurality of photocells and an opposed bottom surface, the module being bounded by a perimeter edge. A mounting frame is secured to the bottom surface of the module. The mounting frame is offset from each of the perimeter edges of the module. The mounting frame includes an upper surface secured to the module and an opposed lower end having a mounting projection.