Pivoting Tab Wire Conduit for Rail-Less Solar Array Installation
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Solution Overview
Problem
The installation of solar panel arrays on residential roofs is arduous and time-consuming due to the complexity of existing assembly components, which often require special tools and are difficult to install, especially in rail-less configurations, and lack effective leveling and electrical bonding solutions.
Innovation Solution
A system of components that includes a barrel nut for adjustable clamps, integrated electrical bonding, a wire management conduit with a pivoting tab, and a latch mechanism for array skirts, allowing for easy installation, leveling, and electrical bonding without additional tools, and accommodating thermal expansion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If traditional clamp assemblies with rotating leveling bolts are used, then leveling adjustment is possible, but the installation process becomes complex and requires special tools
Solution Approach 1:
The patent extracts the leveling adjustment function from a separate rotating leveling bolt and integrates it directly into the clamp assembly structure itself. The clamp includes an adjustable mounting plate with slots and integrated adjustment mechanisms, eliminating the need for external leveling bolts and reducing the number of separate components required for installation.
Solution Approach 2:
The patent merges multiple functions into the clamp assembly: the mounting plate, leveling mechanism, and electrical bonding components are all integrated into a single unified structure. This combination eliminates the need for separate tools and components, allowing installers to complete leveling and electrical bonding during the same installation step.
2Adaptability or versatility
If discrete support elements are used in rail-less configuration, then installation flexibility is improved, but electrical grounding becomes difficult without additional tools
Solution Approach 1:
The patent combines electrical bonding functionality directly into the clamp assembly structure. The mounting plate and clamp components include integrated electrical contact surfaces and conductive paths that automatically establish electrical grounding when the solar panel is installed, eliminating the need for separate grounding tools or steps.
Solution Approach 2:
The clamp assembly performs electrical bonding automatically as part of the mechanical installation process. When the solar panel is secured to the discrete support element, the integrated electrical contacts establish the grounding connection without requiring additional installer actions or specialized tools.
3Reliability
If conventional splice assemblies are used, then array skirts and modules can be joined, but thermal expansion is not accommodated and both sides require electrical bonding
Solution Approach 1:
The patent incorporates dynamic adjustment capabilities into the splice assembly, allowing it to accommodate thermal expansion and contraction of solar panels. The splice includes adjustable mounting plates with slots and movable components that can shift position as panels expand or contract, maintaining reliable electrical contact throughout temperature cycles.
Solution Approach 2:
The splice assembly design allows for parameter adjustments in mounting positions and electrical contact pressures to accommodate environmental changes. The adjustable slots and movable components enable the splice to adapt its geometry and electrical characteristics in response to thermal expansion, maintaining reliable bonding without rigid fixed-position constraints.
Data Source
AI summary
In various representative aspects, an assembly for securing array skirts and solar panel modules in an array on a roof by providing a leveling system that utilizes a barrel bolt and barrel nut to vertically adjust the assembly. Improved electrical bonding by utilizing bonding pins installed in mounting plates of a support clamp are also provided. Additionally, an improved array skirt design that is installed on the outer row of the array, as well as improved designs in the support clamp and splice mechanisms are also provided. Finally, an improved wire management system is included as well as a method of installation of the array assembly.