PV Module Frame Coupling for Strut-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 with rotating and locking portions to interlock frame members, allowing for secure attachment to a mounting surface without external struts, and provides a reliable grounding matrix and adjustable mounting brackets for efficient alignment and installation.
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 increase
Solution Approach 1:
The patent combines the framing function and structural support function into a single integrated frame structure. The frame members are designed to both enclose the PV laminate and provide structural support when coupled together, eliminating the need for separate support members and reducing material usage.
Solution Approach 2:
The frame members are designed to perform multiple functions: enclosing and protecting the PV laminate, providing structural support, enabling mechanical coupling between modules, and facilitating electrical grounding. This multi-functionality eliminates the need for separate components.
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:
By merging the support function into the frame itself, the installation process is simplified to only require coupling the frame members together, eliminating the separate step of installing support members.
Solution Approach 2:
The coupling mechanism includes a rotating portion that allows for dynamic adjustment and easy alignment during installation, making the coupling process faster and more flexible.
3Strength
If separate structural support members are used to span between multiple PV modules, then structural support is provided, but device complexity increases
Solution Approach 1:
The patent merges multiple functions (framing, support, coupling, grounding) into a single integrated system, reducing the total number of components and simplifying the overall assembly process.
Solution Approach 2:
The frame members are designed as universal components that perform multiple functions and can be coupled together in various configurations, reducing system complexity while maintaining structural integrity.
4Reliability
If frame members are interlocked using slidable parallel couplings with rotating and locking portions, then secure attachment is achieved, but manufacturing complexity increases
Solution Approach 1:
The coupling mechanism is divided into distinct functional segments: a slidable coupling body, a rotating portion, and a locking portion. This segmentation allows each component to be manufactured independently using standard machining processes.
Solution Approach 2:
The rotating portion provides a simple mechanical means of locking and unlocking the coupling, using basic rotational motion that is easy to manufacture and operate without complex mechanisms.
5Reliability
If the coupling system provides both structural support and electrical grounding, then system reliability is improved, but device complexity increases
Solution Approach 1:
The patent combines the structural support function and electrical grounding function into the same frame member and coupling mechanism. The frame members serve as both mechanical supports and electrical conductors, eliminating the need for separate grounding components.
Solution Approach 2:
The frame members are designed as multi-functional components that simultaneously provide structural support, mechanical coupling, and electrical grounding pathways, reducing overall system complexity while improving reliability.
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 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 coupling 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 apparatus may further provide a rotating portion and locking portion, mounting brackets for direct connection to a mounting surface, grounding teeth, and a twist-lock engagement means for interlocking and aligning PV modules in the array.