Photovoltaic Module Toe-Slot Coupling for Tool-Free Assembly
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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 design that allows for tool-free assembly, accommodates thermal expansion, and provides 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 and tilted toward the sun, but the mounting components require tools for installation and are prone to loosening due to thermal expansion
Solution Approach 1:
The mounting system is divided into separate functional components: a mounting component with a toe portion for insertion, a toe slot for reception, and a locking surface with a locking toe slot. This segmentation allows each component to perform its specific function independently, enabling tool-free assembly while maintaining secure attachment through the interlocking mechanism.
Solution Approach 2:
The toe portion is inserted into the toe slot, and subsequently the locking toe slot engages with the toe portion through the locking surface. This nested arrangement creates a hierarchical locking structure where the toe portion is first received by the toe slot, then secured by the locking mechanism, providing both ease of installation and reliable retention.
2Reliability
If traditional grounding processes are used, then electrical grounding can be achieved, but material wear occurs leading to increased costs and reduced system reliability
Solution Approach 1:
The mounting component simultaneously performs multiple functions: mechanical attachment through the toe and slot mechanism, and electrical grounding through the conductive mounting component itself. This self-service approach eliminates the need for separate grounding processes that cause material wear, as the mounting component's inherent conductivity provides the grounding path without requiring additional abrasive grounding operations.
3Productivity
If conventional mounting systems are used, then PV modules can be installed, but tool-free assembly is not achieved and installation costs increase
Solution Approach 1:
The mounting component is pre-configured with the toe portion and the mounting chassis is pre-equipped with the toe slot and locking surface. This preliminary preparation of the mounting system allows for rapid, tool-free assembly during installation, as the components are designed to self-align and self-lock without requiring additional tools or complex assembly procedures, thereby increasing productivity and reducing installation costs.
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 enables quick and cost-effective installation of PV modules, enhances system stability by accommodating thermal expansion, and reduces material wear, resulting in a more reliable and durable PV module system.
Implementation Method 1
the slot may be sized to resist removal of the toe portion when the PV module frame expands due to thermal growth
Data Source
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.