PV Module Mounting Clip Structure for Wind Load Resistance
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Solution Overview
Problem
Existing metal clips used to secure photovoltaic module frames to rails are prone to deformation under strong stresses, such as wind forces, leading to failure in maintaining the assembly due to inadequate resistance to torsional and bending deformations, especially with thinner rail materials and larger panel sizes.
Innovation Solution
A clip design featuring interconnected side, upper, and lower walls with grooves and holding flanges that distribute and control forces, including a reinforcing hook and locking mechanism, and a metal strip configuration with bending and tab features to enhance stability and prevent sliding, ensuring robustness against significant external forces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the rail thickness is reduced to save costs, then the manufacturing cost decreases, but the rail becomes more prone to deformation under wind forces
Solution Approach 1:
The clip is designed with distinct functional segments: holding flanges for force distribution, a body for structural support, and end bends with blocking tabs for securing. This segmentation allows each part to optimize its function, with the holding flanges specifically designed to distribute forces over larger contact surfaces on the rail, compensating for the reduced rail thickness
Solution Approach 2:
The blocking tabs extend perpendicular to the plane of the metal strip, adding a third dimension to the force resistance mechanism. These tabs prevent sliding by engaging with the rail in a direction perpendicular to the main force application, providing stability without requiring increased rail thickness
2Productivity
If the panel size is increased to improve productivity, then the energy generation increases, but the wind exposure and tearing forces on clips increase
Solution Approach 1:
Multiple holding flanges are combined along the length of the clip, creating a distributed force resistance system. This merging of multiple contact points allows the clip to handle higher tearing forces from larger panels by spreading the load across multiple locations rather than concentrating it at single points
Solution Approach 2:
The blocking tabs are pre-positioned at the ends of the metal strip to prevent sliding before significant deformation can occur. This preliminary preventive measure ensures that even under high wind loads from large panels, the clip maintains its position and does not slide along the rail
3Force
If the clip is subjected to strong stresses from wind forces, then the holding capacity increases, but the clip deforms by sliding the end bends against each other
Solution Approach 1:
The blocking tabs act as a preliminary protective measure that prevents the end bends from sliding against each other before deformation can occur. By providing this beforehand protection, the clip maintains its structural integrity even when subjected to strong holding forces from wind loads
Solution Approach 2:
The clip utilizes a composite structural approach by combining the metal strip body with integrally formed holding flanges and blocking tabs. This composite design creates a unified structure where each component reinforces the others, preventing deformation while maintaining the ability to withstand strong forces
Data Source
AI summary
A clip for holding two flat elements joined together at their main face. The clip comprises a lower wall, an upper wall, and two side walls, the walls defining a closed volume. The side walls are provided with a groove having an end that opens into a face referred to as the “front face” of the clip. The grooves are configured to insert the clip by its front face onto the two joined flat elements and are each delimited by a contour having an upper segment and a lower segment opposite the upper segment. According to the present disclosure, the side walls each have, on their respective outwardly facing faces, a flat holding flange that extends along a rectilinear portion of the lower segment of the groove and provides a contact surface with one of the flat elements. The present disclosure also relates to an assembly comprising such a clip.