PV Module Mounting Chassis for Tool-Free Thermal Expansion Fit
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Solution Overview
Problem
Existing PV module mounting systems require tools for installation, are prone to loosening due to thermal expansion, and suffer from material wear in the grounding process, leading to increased costs and reduced system reliability.
Innovation Solution
The introduction of PV module couplings with a toe portion and retainer, and a mounting chassis with a grounding plate and locking plate, which allow for tool-free assembly, accommodate thermal expansion, and provide a secure grounding connection through a toe slot and contact surface, respectively.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If traditional mounting components are used to attach the module frame to the module chassis, then the PV panels can be mounted and tilted toward the sun, but the mounting components require tools for installation and are prone to loosening due to thermal expansion
Solution Approach 1:
The mounting component includes a resilient portion that can elastically deform to accommodate thermal expansion and contraction of the PV module frame. This dynamic flexibility allows the mounting system to adapt to temperature changes without loosening, while the resilient nature enables tool-free installation through snap-fit engagement with the module chassis
Solution Approach 2:
The mounting component is divided into distinct functional segments: a resilient portion for elastic deformation and thermal accommodation, a toe portion for engagement with the module frame, and a grounding portion for electrical connection. This segmentation allows each part to perform its specific function optimally while enabling tool-free assembly through modular engagement
2Reliability
If traditional grounding methods are used, then the PV panels can be grounded, but material wear occurs in the grounding process leading to increased costs and reduced system reliability
Solution Approach 1:
The grounding portion is designed with specific dimensional parameters and material properties that reduce friction and wear during the grounding process. The geometry and surface characteristics are optimized to minimize material loss while ensuring reliable electrical contact between the PV module frame and the grounding system
Solution Approach 2:
The mounting component may utilize composite material construction or material combinations that provide both electrical conductivity for grounding and low friction properties to reduce wear. This allows the grounding portion to maintain reliable electrical contact while minimizing material degradation over time
3Productivity
If tool-free assembly is implemented, then installation time is reduced, but the mounting system must accommodate thermal expansion without tools
Solution Approach 1:
The resilient portion provides dynamic adaptability through elastic deformation, allowing the mounting component to accommodate thermal expansion and contraction of the PV module frame. This same resilient mechanism enables tool-free installation through snap-fit engagement, where the elastic deformation facilitates easy attachment and detachment without requiring tools
Data Source
AI summary
Mounting components of photovoltaic (PV) modules and PV module assemblies are described, including PV module couplings and PV module mounting chassis. In an example, a PV module includes a PV module coupling having a toe portion extending from a PV module frame, and a PV module mounting chassis includes a toe slot to receive the toe. The toe and toe slot construction allows for the PV module frame to be assembled to the PV module mounting chassis without using tools, and thus, permits a PV module assembly to be quickly constructed during installation of a PV module system. Furthermore, the toe and toe slot construction accommodates thermal expansion and other environmental loads seen after installation, while providing a grounding connection for the PV module assembly.