PV Module Frame Coupling for Support-Free Array Mounting
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Solution Overview
Problem
Existing photovoltaic (PV) module mounting systems require separate structural support members that span between multiple PV modules, leading to increased material costs, installation time, and complexity in forming and mounting PV arrays on surfaces like roofs.
Innovation Solution
A PV module framing and coupling system that uses slidable parallel couplings to interlock frame members, providing a rotating and locking mechanism for secure attachment to a mounting surface, and a twist-lock engagement system for reliable alignment and grounding, eliminating the need for separate structural support members.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If separate structural support members are used to span between multiple PV modules, then structural support is provided, but material costs, installation time, and complexity increase
Solution Approach 1:
The frame members are designed to perform multiple functions simultaneously: they provide structural support for the PV modules, serve as mounting surfaces for direct attachment to the roof, and act as interlocking elements through the coupling mechanism. This eliminates the need for separate structural support members, reducing material costs and installation complexity while maintaining structural integrity
Solution Approach 2:
The frame members are designed as universal components that can directly attach to mounting surfaces and interlock with adjacent modules. The coupling mechanism enables the frame members to provide both structural support and mounting functions, making the system more versatile and reducing the number of separate components needed
2Strength
If separate structural support members are used to span between multiple PV modules, then structural support is provided, but installation time increases
Solution Approach 1:
The frame members are pre-designed with integrated coupling mechanisms and mounting interfaces. The coupling devices can be attached to frame members before installation, and the frame members are prepared with pre-drilled holes and mounting features. This preliminary preparation significantly reduces on-site installation time while maintaining structural support requirements
Solution Approach 2:
By combining the structural support function with the mounting function in a single integrated system, the number of installation steps is reduced. The frame members directly attach to the roof and interlock with adjacent modules, eliminating the need to install separate support structures first
3Strength
If separate structural support members are used to span between multiple PV modules, then structural support is provided, but material costs increase
Solution Approach 1:
The frame members are designed to combine multiple functions into single components: structural support, mounting attachment, and interlocking. This consolidation eliminates the need for separate structural support members, directly reducing material quantity and costs while maintaining the required structural strength through optimized frame member design
Solution Approach 2:
The universal frame members serve multiple purposes simultaneously, reducing the total material required. The same frame members that provide structural support also serve as mounting surfaces and interlocking elements, maximizing material efficiency and reducing overall system cost
4Strength
If slidable parallel couplings are used to interlock frame members, then structural load distribution is improved, but device complexity increases
Solution Approach 1:
The coupling mechanism is divided into discrete, modular components: the coupling device itself, the locking mechanism, and the sliding interface. This segmentation allows each component to be optimized for its specific function while maintaining overall simplicity. The modular design makes the complex load distribution function achievable through relatively simple, standardized parts
Data Source
AI summary
A photovoltaic (PV) module framing and coupling system enables the attachment of PV modules to a roof or other mounting surface without requiring the use of separate structural support members which attach directly to and span between multiple PV modules in a formed PV array. The inventive apparatus provides a parallel coupling for securely interlocking the outside surfaces of parallel frame members together in a side to side arrangement to form an array with improved structural load distribution. The inventive coupling member may attach to a slot in the frame at substantially any position along the length of the frame thereby enabling the interconnection of adjacent PV modules along both an x and y axis. The inventive apparatus may further provide a rotating portion and locking portion for coupling to frame attachment, mounting brackets for direct connection to a mounting surface, grounding teeth for the automatic creation of a reliable two axis grounding matrix, and a rapid twist-lock engagement means for reliably interlocking and aligning PV modules in the array.