PV Wire Cover Assembly for Non-Penetrating Panel Mounting
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Solution Overview
Problem
Solar panel array failures often occur due to damage of connecting wires, particularly at connectors, and the need for wire protection from environmental exposure and theft, without requiring drilling holes into the panels for mounting.
Innovation Solution
A photovoltaic panel wire cover assembly using clips and an elongate wire cover that can be fastened to the panel perimeter without penetrating it, providing protection and theft deterrence while accommodating varying panel spacings and using secure fasteners.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If wires are provided with minimal insulation and light configuration to reduce cost, then manufacturing expense is reduced, but wire protection from environmental damage and theft is insufficient
Solution Approach 1:
The wire protection system is segmented into separate components: the wire itself maintains minimal insulation for cost-effectiveness, while protection is provided by separate elements including an elongate cover that encloses the wire and clips with flanges that attach to panel perimeters. This segmentation allows the wire to be manufactured simply while protection is added through separate, targeted components.
Solution Approach 2:
An elongate cover acts as an intermediary element between the wire and the environmental threats. The cover encloses the wire, providing protection from theft and environmental damage without requiring changes to the wire's basic structure or insulation. The clips serve as intermediaries to attach the cover system to the panel perimeter.
2Strength
If fasteners penetrate the PV panel to secure the wire cover, then mounting security is improved, but panel integrity is compromised
Solution Approach 1:
The mounting function is extracted from the panel itself and transferred to the perimeter trim piece. Clips are designed to attach to the perimeter trim rather than penetrate the panel, separating the mounting operation from the panel structure. This extraction allows secure mounting while preserving panel integrity.
Solution Approach 2:
The perimeter trim piece serves as an intermediary mounting surface between the wire cover system and the panel. Clips attach to this trim piece, which itself is attached to the panel edge, providing a secure mounting path that does not require penetrating the panel face.
3Stability of the object's composition
If clips are designed to fit tightly on perimeter trim pieces, then wire cover stability is improved, but adaptability to varying panel spacings is reduced
Solution Approach 1:
The clip assembly incorporates dynamic adjustment capability through the relationship between the flange position and the clip's engagement with the perimeter trim. The system can be adjusted along the perimeter to accommodate varying panel spacings while maintaining stable attachment through the clip's gripping action on the trim piece.
Data Source
AI summary
A photovoltaic panel wire cover assembly, used with a PV panel having a perimeter trim piece, includes clips, an elongate wire cover and fastener structure. Each clip includes a proximal end and long and short legs, the long leg parallel with and joined to the short leg at the clip proximal end. A gap between the long and short legs is sized for receipt of the trim piece. The wire cover includes a wire-covering housing defining a housing interior and having first and second opposite sides and a first flange extending from the first opposite side and positioned against the long leg. The fastener structure engages the short leg and the first flange to bias the first flange and the long leg therewith towards the short leg. The wire cover can be fastened to the trim piece through the clips without penetrating the PV panel.