Rail-less solar panel assembly and installation method
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Solution Overview
Problem
The installation of solar panel arrays on residential roofs is arduous and time-consuming, particularly in rail-less configurations, due to the difficulty in adjusting and leveling clamp assemblies, electrical bonding requirements, and lack of efficient wire management, often necessitating additional tools and complex mechanisms.
Innovation Solution
A system utilizing a barrel nut with a drive head for adjustable clamps, linear bonding pins and clamps for electrical bonding, and a wire management conduit with a pivoting tab to simplify the installation process, eliminate the need for rotating leveling bolts, and secure wires safely.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a rotating leveling bolt is used to adjust clamp assemblies, then the clamp can be adjusted for leveling, but the installation becomes more complex and requires additional tools and custom bolts
Solution Approach 1:
The patent removes the rotating leveling bolt mechanism from the clamp assembly, extracting the complex adjustment mechanism and replacing it with a simpler barrel nut system that integrates directly into the clamp structure, eliminating the need for custom bolts and reducing tool requirements
Solution Approach 2:
The barrel nut is designed to be self-contained within the clamp assembly, allowing installers to perform leveling adjustments from above the clamp using the barrel nut itself without requiring external adjustment mechanisms or specialized tools, making the system self-sufficient
2Reliability
If array skirts or solar panel modules are electrically bonded on both sides of the splice, then electrical connectivity is ensured, but the system loses adaptability for thermal expansion and adjustments
Solution Approach 1:
The patent applies electrical bonding only to one side of the splice (either the array skirt or the solar panel module) rather than both sides, creating a localized bonding approach that maintains electrical connectivity while leaving the other side free to move, thereby accommodating thermal expansion and installation adjustments
3Productivity
If discrete support elements are used in a rail-less configuration, then the solar panel array can be installed without rails, but the installation becomes arduous and time-consuming
Solution Approach 1:
The patent combines multiple functions into the clamp assembly: mechanical support, electrical bonding, and leveling adjustment are all integrated into a single component system. The mounting plate with integrated conduit and the barrel nut mechanism allow installers to complete multiple tasks (securing panels, managing wires, and leveling) in sequence without switching between different adjustment mechanisms, significantly improving installation efficiency
Data Source
AI summary
In various representative aspects, an assembly for securing array skirts and solar panel modules in an array on a roof by providing a leveling system that utilizes a barrel bolt and barrel nut to vertically adjust the assembly. Improved electrical bonding by utilizing bonding pins installed in mounting plates of a support clamp are also provided. Additionally, an improved array skirt design that is installed on the outer row of the array, as well as improved designs in the support clamp and splice mechanisms are also provided. Finally, an improved wire management system is included as well as a method of installation of the array assembly.