PV Module Bracket with Self-Locking Tabs for Tool-Free Mounting

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Solution Overview

Problem

Traditional photovoltaic (PV) frame-attach systems require additional components and time for mounting a power conditioner to a PV module frame, involving multiple bolts and drilling holes, which is inefficient.

Innovation Solution

A flexible-plate bracket with self-locking features, including offset tabs and spring clips, allows secure coupling of a power conditioner to a PV module frame without holes or secondary fasteners, enabling easy removal and installation without special tools.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If traditional mounting systems use multiple bolts and adapter plates, then the connection strength is sufficient, but the device complexity and assembly time increase significantly

Engineering Contradiction:

Improveconnection strengthVSAvoidmounting system complexity

Core Design Contradiction:

StrengthVSDevice complexity

Solution Approach 1:

The mounting bracket integrates multiple functions into a single component: it combines the adapter plate, mounting bracket, and fastening mechanism into one unified structure that attaches directly to the PV module frame corners, eliminating the need for separate adapter plates and multiple bolts

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The invention extracts and eliminates unnecessary intermediate components from the traditional mounting system, removing adapter plates and reducing multiple fasteners to a single integrated bracket with built-in fastening features

Inventive Principle:

Principle #2Taking out (Extraction)

2Strength

If traditional systems use multiple bolts requiring specific torque, then the retention force is sufficient, but the assembly time and effort increase

Engineering Contradiction:

Improveretention forceVSAvoidassembly time

Core Design Contradiction:

StrengthVSLoss of time

Solution Approach 1:

The mounting bracket incorporates self-aligning and self-fastening features that automatically position and secure the power conditioner to the PV module frame without requiring manual alignment or torque-controlled fastening operations

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The invention replaces the complex mechanical fastening system requiring multiple bolts and torque control with a simplified single-bracket system that uses integrated fastening features for quick attachment

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Reliability

If traditional systems require drilling holes and assembling multiple components, then the mounting is secure, but the ease of manufacture and installation deteriorates

Engineering Contradiction:

Improvemounting securityVSAvoidinstallation ease

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The mounting bracket is pre-configured with built-in fastening features and attachment points during manufacturing, allowing for tool-free or minimal-tool installation by simply positioning and securing the single bracket to the PV module frame corners

Inventive Principle:

Principle #10Preliminary action

Data Source

PatentUS10686399B2Apparatus for mounting a power conditioner to a photovoltaic module frame

Publication Date: 2020.06.16 ENPHASE ENERGY INC

AI summary

An apparatus for mechanically coupling a power conditioner to a photovoltaic (PV) module frame. In one embodiment, the apparatus comprises: a bracket, adapted for mechanically coupling the power conditioner to the PV module frame, comprising at least one inner-flange tab and at least one outer-flange tab for trapping a flange of the PV module frame between them; and at least one self-locking mounting structure for locking the bracket to the PV module frame without requiring any holes in the PV module frame.