Photovoltaic Module Mounting Structure With Integrated Grounding
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Solution Overview
Problem
Conventional photovoltaic modules with resin frame bodies face challenges in grounding, leading to complex and time-consuming mounting processes when the entire housing is not made of metal, requiring additional grounding steps and torque management during assembly.
Innovation Solution
A mounting structure featuring a metal bottom plate with a resin side wall frame, utilizing a rivet and washer system for secure fastening and grounding, eliminating the need for separate grounding connections and torque management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If the frame body is formed from resin to reduce weight and cost, then the weight and manufacturing cost decrease, but grounding becomes difficult and mounting process complexity increases
Solution Approach 1:
The patent combines the fastening function and grounding function into a single integrated mounting structure. The clamp member with metal cladding not only mechanically fastens the photovoltaic module to the support rail but also simultaneously provides electrical grounding through the conductive metal cladding that contacts the module's frame. This eliminates the need for separate grounding connections and torque management procedures.
Solution Approach 2:
The mounting structure achieves multi-functionality by making the clamp member serve dual purposes: structural fastening and electrical grounding. The metal cladding on the resin clamp body provides both mechanical strength for secure attachment and electrical conductivity for grounding, allowing one component to replace what would traditionally require multiple separate components and procedures.
2Ease of manufacture
If the frame body is formed from resin to reduce cost, then manufacturing cost decreases, but additional grounding equipment and elements are required
Solution Approach 1:
The patent merges the grounding function into the fastening component itself. The metal cladding on the clamp member serves as both the fastening element and the grounding path, eliminating the need for separate grounding wires, connectors, or additional grounding equipment. This integration maintains cost-effectiveness while removing the complexity of separate grounding systems.
Solution Approach 2:
The clamp member is designed with universal functionality, where the same component that provides mechanical attachment also provides electrical grounding. The metal cladding material and its contact configuration enable it to perform both fastening and grounding roles, replacing what would traditionally require multiple specialized components.
3Reliability
If torque management is required during assembly, then fastening reliability improves, but assembly time and operational complexity increase
Solution Approach 1:
The mounting structure employs self-clamping mechanics where the clamp member is designed to automatically apply and maintain appropriate clamping force through its mechanical design. The clamp engages with the support rail and photovoltaic module frame in a way that self-regulates the fastening force, eliminating the need for external torque control mechanisms, torque wrenches, or complex assembly procedures. The structure itself ensures reliable fastening through its geometric design and material properties.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Facilitates the mounting of photovoltaic modules by simplifying the fastening process and ensuring electrical grounding, reducing the need for additional grounding connections and minimizing manual labor.
Implementation Method 1
an other end portion of the shank portion being deformed so as to have an enlarged diameter
Implementation Method 2
a housing having a metal bottom plate on which the plurality of power generating elements are arrayed
Data Source
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AI summary
A mounting structure for a photovoltaic module, the photovoltaic module including: a plurality of power generating elements; and a housing having a metal bottom plate on which the plurality of power generating elements are arrayed, and a resin side wall frame standing along an outer edge of the bottom plate, the mounting structure including: a support plate having a support face configured to be in contact with an outer face of the bottom plate to support the photovoltaic module; a washer to be disposed on one face which is an inner face of the bottom plate or a face, of the support plate, at a side opposite to the support face; and a rivet having a shank portion and a head, the shank portion being configured to be passed through the support plate and the bottom plate to be inserted into the washer, the head formed at one end portion of the shank portion, the rivet being configured to sandwich and fasten the support plate and the bottom plate between the washer and the head by an other end portion of the shank portion being deformed so as to have an enlarged diameter.