PV Module Coupling Frame for Support-Free Array Mounting
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing photovoltaic (PV) module mounting systems require separate structural support members that span between multiple PV modules, leading to increased costs and installation time due to the need for additional materials and complex connections.
Innovation Solution
A PV module framing and coupling system that enables direct attachment to a roof or mounting surface without separate structural support members, utilizing a slidable parallel coupling for interlocking adjacent modules, a rotating locking mechanism, and adjustable brackets for secure alignment and grounding, allowing for improved structural load distribution and simplified 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 costs and installation time increase due to additional materials and complex connections
Solution Approach 1:
The patent combines the framing function and structural support function into a single integrated PV module frame system. The frame members directly provide both the enclosure for PV laminates and the structural support for the entire array, eliminating the need for separate support members and reducing system complexity while maintaining structural integrity
Solution Approach 2:
The PV module frame serves multiple functions simultaneously: it encloses and protects PV laminates, provides structural support for the array, enables interconnection between modules, and facilitates mounting to surfaces. This multi-functionality eliminates the need for separate dedicated support structures, reducing both material costs and installation complexity
2Strength
If separate structural support members are used to span between multiple PV modules, then structural support is provided, but installation time increases due to additional materials and complex connections
Solution Approach 1:
The mounting system is segmented into modular PV modules with integrated frames that can be independently assembled and then connected together. This segmentation allows for pre-assembly of modules and simplifies the overall installation process, as modules can be installed sequentially without requiring complex coordination of separate support structures
Solution Approach 2:
By merging the framing and structural support functions into a single integrated system, the number of installation steps is reduced. The frame members directly provide both enclosure and structural support, eliminating the need to separately install support members and connect them to modules, thereby significantly reducing installation time
3Strength
If additional structural elements are added to span between PV modules, then structural integrity is enhanced, but costs increase due to additional materials
Solution Approach 1:
The PV module frame is designed to serve multiple functions including enclosure, structural support, and interconnection. By making the frame multi-functional, the system achieves enhanced structural integrity without requiring additional dedicated support elements, thereby reducing material quantity and cost while maintaining structural performance
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.