Photovoltaic Module Rail With Clip Fasteners for Faster Assembly
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Solution Overview
Problem
The assembly of photovoltaic systems is time-consuming and costly due to the complexity of mounting photovoltaic modules on racking assemblies, which involves multiple components and requires significant labor and resources.
Innovation Solution
A module rail system with a module-supporting surface, vertical sidewall, and fastener openings that utilize clip fasteners to securely mount photovoltaic modules, allowing for efficient and rapid assembly by reducing the need for extensive tooling and labor through the use of top-down fasteners and clip fasteners that provide structural support and electrical grounding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional mounting methods with multiple components are used, then structural stability is improved, but assembly time and labor costs increase
Solution Approach 1:
The patent combines the mounting function and fastening function into a single integrated module rail component. The rail includes integrated features for supporting photovoltaic modules and securing them with fasteners, eliminating the need for separate mounting brackets and fasteners. This merging of functions reduces the number of components and assembly steps while maintaining structural stability.
Solution Approach 2:
The module rail is designed as a multi-functional component that simultaneously provides structural support, module positioning, and fastening capabilities. The rail includes features such as support surfaces for holding modules, integrated fastener openings for securing modules, and positioning features for alignment. This multi-functionality allows a single component to replace multiple traditional components, reducing assembly complexity and time.
2Ease of repair
If multiple separate components are used for mounting, then ease of repair is improved, but device complexity increases
Solution Approach 1:
The patent divides the mounting system into modular components: the module rail and the photovoltaic modules themselves. Each module can be independently installed, removed, and replaced on the rail system. The fastener openings in the rail allow for quick attachment and detachment of individual modules without affecting other modules or the rail structure, maintaining ease of repair while reducing overall system complexity.
3Strength
If traditional fastening methods are used, then structural integrity is improved, but manufacturing precision requirements increase
Solution Approach 1:
The module rail is pre-manufactured with precisely positioned fastener openings and positioning features during the rail fabrication process. These features are built into the rail structure at predetermined locations and orientations, eliminating the need for field alignment and adjustment during installation. The preliminary preparation of these features ensures both structural integrity and reduced manufacturing precision requirements during assembly.
Data Source
AI summary
A module rail for a photovoltaic system includes a module-supporting surface extending along the length of the module rail for supporting at least one photovoltaic module thereon. A vertical sidewall extends downward from a side of the module-supporting surface. Fastener openings are spaced apart from one another along the length of the rail. Each of the fastener openings extend through the sidewall generally adjacent to a juncture of the module-supporting surface and the sidewall. Each of the fastener openings is configured to receive a clip fastener for securing a photovoltaic module on the module-supporting surface.