PV Array Interconnection Mounting for Redeployable Geomembranes
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Solution Overview
Problem
Existing photovoltaic (PV) panel mounting systems on geomembranes face challenges such as adhesive failures due to thermal expansion differences, difficulty in maintenance and replacement, and inability to redeploy the solar arrays, especially on uneven or shifting surfaces like landfills and brownfields, where conventional systems cause panel breakage and require costly permanent attachments.
Innovation Solution
A novel mounting system comprising standoff mounts, elongated mounting rails, and attachment rails that allow for flexible installation and removal, using various attachment methods like adhesive bonding, ultrasonic welding, or annular bonding rings, and incorporating ballast trays for securement on uneven surfaces, enabling the PV panels to be easily reconfigured, removed, or replaced, and allowing relative movement to reduce stress and damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If flexible PV panels are directly adhered to the geomembrane surface using adhesive backing, then the system provides flexibility and movement capability to accommodate waste settlement, but the adhesive layer fails due to thermal expansion differences between panels and membrane, causing panel and membrane damage
Solution Approach 1:
The patent introduces an intermediary mechanical mounting system consisting of rails, brackets, and fasteners that couple the PV panels to the geomembrane without relying on adhesive bonding. This mechanical intermediary allows both the panel and membrane to move relative to each other while maintaining secure attachment, eliminating thermal expansion-induced adhesive failure.
Solution Approach 2:
The mounting system incorporates dynamic elements such as slotted holes in brackets and adjustable fasteners that allow the PV panels to move with the geomembrane as it settles or expands thermally. This dynamic capability maintains the adhesive-free mechanical bond integrity under varying thermal and settlement conditions.
2Strength
If conventional rigid solar arrays with metal frames and concrete bases are used, then structural strength and stability are improved, but the weight causes movement and breakage on uneven settling landfill surfaces
Solution Approach 1:
The patent employs flexible lightweight mounting components including thin-walled metal or polymer rails, brackets, and fasteners that provide sufficient structural strength while maintaining low weight. These flexible components can accommodate surface irregularities and settlement without causing panel breakage, unlike rigid concrete bases.
Solution Approach 2:
The mounting system is segmented into discrete lightweight components (rails, brackets, fasteners) rather than a monolithic heavy structure. This segmentation allows each component to independently accommodate local settlement while maintaining overall array stability, preventing catastrophic panel breakage.
3Ease of manufacture
If PV panels are adhered directly to the membrane, then installation is simplified, but maintenance and replacement become difficult due to permanent attachment
Solution Approach 1:
The mechanical mounting system uses removable fasteners and sliding brackets that allow panels to be easily detached and reattached. This dynamic mechanical connection maintains installation simplicity while enabling straightforward maintenance and replacement, unlike permanent adhesive bonds.
Solution Approach 2:
The system segments the panel attachment into discrete mechanical components (brackets, fasteners, rails) that can be independently assembled and disassembled. This modular segmentation simplifies both initial installation and subsequent maintenance operations compared to monolithic adhesive bonding.
4Strength
If adhesive bonding is used to attach panels to geomembrane, then initial attachment is secure, but the system cannot be redeployed or reconfigured as needed
Solution Approach 1:
The mechanical mounting system provides secure attachment through friction-fit rails and fastened brackets while maintaining full reversibility. Panels can be removed and reinstalled in different locations or configurations, providing deployment flexibility that permanent adhesives cannot achieve.
Solution Approach 2:
The reusable mechanical mounting components (rails, brackets, fasteners) can be recovered and redeployed with different PV panels or at different locations. This recoverability enables system reconfiguration and redeployment, unlike consumable adhesive bonds.
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
The system facilitates rapid, cost-effective installation and maintenance of PV arrays, reduces panel and membrane damage by allowing movement, and enables redeployment, improving the longevity and adaptability of solar installations on geomembranes.
Implementation Method 1
using various attachment methods like adhesive bonding, ultrasonic welding, or annular bonding rings
Data Source
AI summary
A mount system for a photovoltaic (PV) panel array allows for ease of installation, flexibility of movement, and the ability to remove and redeploy the system as needed. The system includes a plurality of modules which support a PV panel and a plurality of purlin connectors which interconnect with the modules. The system further includes a plurality of electrical connections which allow each of the modules to be in electrical communication with one another and may further a junction box, also in electrical communication with the modules.