Multi-Part PV Module Frame With Integrated Sealing and Ventilation
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Solution Overview
Problem
Existing roof mounting systems for photovoltaic systems, particularly in-roof and full-roof systems, face challenges such as complex assembly, high material and labor costs, poor ventilation and cooling, and aesthetic unappeal, leading to lower yields and limited market adoption due to numerous components and complex connections.
Innovation Solution
A multi-part frame system comprising a retaining profile with latched sealing lips and a sealing profile that ensures watertightness and stability, allowing for easy assembly and tool-free module replacement, with adaptable retaining hooks and support profiles for various module thicknesses and loads, and integrated drainage to prevent frost damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If a stable frame and mounting system are used to absorb forces in rooftop systems, then structural stability is improved, but material consumption and device complexity increase
Solution Approach 1:
The mounting system is divided into separate functional components: a retaining profile for mechanical attachment and a sealing profile for weatherproofing. This segmentation allows each component to be optimized independently, reducing overall material consumption while maintaining structural stability.
Solution Approach 2:
The retaining profile serves multiple functions: it provides structural support, absorbs mechanical forces, and integrates the sealing function through the attached sealing lip profile. This multi-functionality eliminates the need for separate stabilization components, reducing material consumption.
2Stability of the object's composition
If a large number of components are used in rooftop systems, then structural stability is improved, but assembly complexity and labor costs increase
Solution Approach 1:
The retaining profile and sealing profile are merged into a single integrated component. The sealing lip profile is attached to the retaining profile, creating a unified assembly that reduces the number of parts from multiple separate components to just two main profiles, significantly simplifying assembly.
Solution Approach 2:
The integrated profile performs multiple functions simultaneously: mechanical retention, force absorption, and weather sealing. This multi-functionality eliminates the need for separate stabilization and sealing components, reducing assembly complexity.
3Reliability
If traditional sealing profiles are used in overlapping areas, then tightness is improved, but assembly complexity and material consumption increase
Solution Approach 1:
The sealing lip profile is integrated with the retaining profile, combining sealing and structural functions into one component. This reduces the number of separate sealing components needed in overlapping areas, simplifying assembly while maintaining tightness.
Solution Approach 2:
The sealing lip profile includes a flexible sealing element that can deform to accommodate manufacturing tolerances and roof irregularities. This dynamic sealing mechanism ensures tightness without requiring precise assembly or additional adjustment components.
4Stability of the object's composition
If multiple carrier profiles are used to hold solar elements, then structural stability is improved, but device complexity and assembly time increase
Solution Approach 1:
The mounting system uses only two carrier profiles (one at each end of the module) instead of multiple profiles along the length. This segmentation approach maintains structural stability while dramatically reducing the number of components to be assembled.
Solution Approach 2:
The retaining profile serves as both a structural support element and a mounting element for the solar module. This multi-functionality eliminates the need for separate carrier profiles, reducing assembly time while maintaining stability.
Data Source
Figure 1
Figure 2a~2c
Figure 3a~3c
AI summary
The profile (2) has a multi-part structure consisting of a retaining hook (11) connected with a retaining strip (10), where the profile is made of plastic or metal i.e. aluminum. Profile bodies are formed by connection of the retaining strip and the retaining hook. Upper and lower plate-like modules (3) are held at a retaining structure i.e. roof substructure in an overlapping condition so that the profile bodies sectionally extend between the modules. The connection of the retaining strip and the retaining hook is formed by locking. An independent claim is also included for a multipart frame comprising a sealing profile.