Photovoltaic Mounting Bracket With Form-Fit Variable Stiffness
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Solution Overview
Problem
Existing mounting brackets for photovoltaic modules lack defined elastic properties and are costly to manufacture, with gluing methods being time-consuming and leading to inconsistent performance due to adhesive layers and complex assembly processes.
Innovation Solution
A form-fitting connection between a retaining bracket and a reinforcement bracket, using bending shackles and recesses, creates a uniform, easy-to-handle unit that eliminates the need for adhesives and allows precise alignment and control of elastic properties, enabling efficient and cost-effective production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If mounting brackets are made from a single piece of flat material with uniform thickness, then manufacturing is simple and cost-effective, but the bracket has the same stiffness throughout its entire length which is undesirable as it cannot provide both flexibility in the holding area and rigidity in the screw connection area
Solution Approach 1:
The mounting bracket is divided into two separate parts: a holding bracket with the C-shaped bend for holding the module, and a reinforcement bracket that provides additional stiffness in the screw connection area. These two brackets are then connected through a form-fitting connection, allowing each part to be optimized independently for its specific function while maintaining manufacturing simplicity.
2Strength
If mounting brackets are assembled from two separate parts (holding bracket and reinforcement bracket), then the desired increase in flexural rigidity in the screw connection area is achieved, but the two parts must be held together captively before screwing to the support structure to facilitate transport and assembly
Solution Approach 1:
The holding bracket is prepared in advance with bending shackles that protrude from its surface. These bending shackles are designed to fit into corresponding recesses in the reinforcement bracket, creating a form-fitting connection that automatically aligns and secures the two parts together during assembly, eliminating the need for additional fastening steps.
3Ease of operation
If the two parts of the mounting bracket are glued together to facilitate transport and assembly, then handling is simplified, but gluing is relatively expensive and no longer allows subsequent correction if the screw holes in the two parts are not sufficiently aligned
Solution Approach 1:
The adhesive bonding system is replaced with a mechanical form-fitting connection system. The bending shackles on the holding bracket fit into recesses in the reinforcement bracket, creating a secure mechanical interlock that can be assembled without adhesives. This mechanical connection allows for adjustment and correction if alignment issues arise, while also reducing manufacturing costs.
4Quantity of substance
If the mounting bracket is produced in one piece from flat material with a 180° bend in the screw connection area to increase rigidity, then material usage is reduced, but the 180° bend is very critical and can lead to undesired breaking of the material
Solution Approach 1:
Instead of creating a 180° bend in a single-piece bracket, the design segments the bracket into two separate parts connected by bending shackles. This eliminates the need for critical 180° bends in the main structure, as the connection between parts is achieved through smaller, less stressful bends in the bending shackles that fit into recesses, significantly reducing the risk of material failure.
Data Source
Figure 1a
Figure 1b
Figure 2~3
AI summary
The mounting casing has screw fastening region (2) that is provided with screw-hole (4a) for bolting to support structure. A retaining region (3) is provided for retaining to-be-fixed object. A double-opposing crank (5) is positioned between screw fastening region and retaining region. The mounting casing is provided with analog double-bend support casing (6) and reinforcing casing (7) that are connected to each other in opposite direction. A form-fitting connection is provided between support casing and reinforcing casing via double-opposing crank. Independent claims are included for the following: (1) a method for manufacturing the mounting casing; and (2) a kit for containing the mounting casing.