Photovoltaic Wire Management Duct with Mounting Lip
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Solution Overview
Problem
Existing wire management systems for photovoltaic solar arrays are inefficient, as they often require cables to be secured under tension, which can lead to damage and electrical hazards due to sharp edges, and are not universally compatible with different PV module brands and racking systems, lacking durability and ease of installation.
Innovation Solution
A wire management duct with a wire channel and mounting lips that securely attach to photovoltaic rail mounting systems, allowing cables to be laid and secured without tension, featuring a curved section terminating at a hook for easy mounting and a channel design that prevents accidental dislodgment of wires, ensuring compatibility with various PV modules and racking systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If zip ties or wire clips are used to secure wires to module frames or rails, then wires can be attached, but the installation is time-consuming and the wires can be damaged by sharp edges
Solution Approach 1:
The patent introduces a wire management duct as an intermediary component between the wire and the mounting structure. The duct has a smooth interior surface that prevents wire damage from sharp edges, while the exterior includes mounting features that attach to module frames or rails. This mediator protects the wire from harmful factors while enabling secure attachment.
Solution Approach 2:
The wire management duct is made from a flexible or semi-rigid material that can be bent and shaped to route wires along desired paths. The duct's flexible nature allows it to conform to the contours of module frames and rails while maintaining protection for the wires inside, eliminating the need for sharp-edged clips or ties.
2Stability of the object's composition
If wires are installed under tension to prevent sagging, then wires stay above the roof surface, but thermal expansion can cause wires to shrink and pull out of attachments or connectors
Solution Approach 1:
The wire management duct provides a protective channel that cushions wires against thermal expansion and contraction forces. The duct's flexible material absorbs the stress of wire movement due to temperature changes, preventing wires from pulling out of connectors or attachments while maintaining stable wire positioning throughout the year.
3Object-affected harmful factors
If large-scale cable trays are used for wire management, then cable protection is improved, but they cannot attach to rails and module frames and interfere with racking components
Solution Approach 1:
The patent divides the wire management system into segmented, modular duct sections that can be individually attached to rails and module frames. Instead of using a single large-scale cable tray that interferes with racking components, the system uses multiple smaller duct segments that route wires along the edges and surfaces of racking components without blocking or interfering with their function.
Data Source
AI summary
A wire management duct having is provided with a wire channel along the length of the duct. In an embodiment, the duct is further comprising a mounting lip to mount the duct onto a mounting rail of photovoltaic array mounting rail system. In another embodiment, a wire management system is comprised of one or more wire management ducts which may be mounted parallel to the mounting rails of photovoltaic array mounting rail system or perpendicular to the rails using an attachment clip. In a further embodiment, mounting clips are provided to attach the wire management ducts directly to the frame of a photovoltaic module.