Pivot-Fit Frame Connection for Rapid PV Module Assembly
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Solution Overview
Problem
Existing photovoltaic (PV) module coupling systems face challenges such as high part count and slow installation times due to the need for multiple small fasteners, inability to account for manufacturing tolerances, unreliable electrical ground bonds, and loose connections prone to loosening under mechanical stress.
Innovation Solution
A pivot-fit connection system using angled grooves and couplings that allow PV modules to be easily assembled and adjusted, providing a sturdy and durable connection while accommodating dimensional variations and ensuring reliable electrical grounding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of time
If press-fit connections are used to reduce fastener usage, then installation time is reduced, but the connection cannot adequately account for dimensional variations from manufacturing tolerances
Solution Approach 1:
The connection system uses a dynamic adjustment mechanism where the second module can be positioned and secured at multiple locations along the connection element, allowing the system to adapt to dimensional variations in real-time during installation rather than requiring precise pre-manufactured fits
Solution Approach 2:
The connection element is divided into multiple engagement locations or positions that can accommodate modules with varying dimensions, allowing selective engagement at different points to compensate for manufacturing tolerances
2Ease of operation
If hook-type connections are used to simplify assembly, then ease of operation is improved, but reliable electrical ground bond cannot be provided
Solution Approach 1:
The connection element integrates both mechanical connection functions and electrical grounding functions into a single component, eliminating the need for separate grounding fasteners while maintaining ease of assembly through a single engagement action
Solution Approach 2:
The connection element serves multiple functions simultaneously: it provides mechanical support, enables electrical connection, and establishes ground bonding, replacing the need for multiple specialized components
3Ease of operation
If female receiving portion is made wider than male connecting portion for quick connection, then ease of operation is improved, but connection becomes loose and vulnerable to loosening
Solution Approach 1:
The connection system transitions from a static wide-opening design to a dynamic insertion process where the module is initially engaged at an angle and then rotated into a locked position, providing both ease of insertion and secure final connection
Solution Approach 2:
The connection mechanism uses angular and rotational movements rather than linear insertion, where the module is inserted at an angle and then rotated to engage locking features, providing secure connection without requiring a wide opening
4Strength
If multiple small fasteners are used to provide strong connection, then connection strength is improved, but part count increases and installation time increases
Solution Approach 1:
Multiple fastening functions are merged into a single connection element that provides both mechanical support and electrical connection through one engagement action, eliminating the need for multiple separate fasteners
Solution Approach 2:
The connection element is designed to perform multiple functions simultaneously including mechanical attachment, electrical bonding, and structural support, replacing what would traditionally require multiple specialized components
Data Source
AI summary
A system and apparatus are disclosed including PV modules having a frame allowing quick and easy assembling of the PV modules into a PV array in a sturdy and durable manner. In examples of the present technology, the PV modules may have a grooved frame where the groove is provided at an angle with respect to a planar surface of the modules. Various couplings may engage within the groove to assemble the PV modules into the PV array with a pivot-fit connection. Further examples of the present technology operate with PV modules having frames without grooves, or with PV modules where the frame is omitted altogether.