Rail-mounted bottom clamp for mounting solar panels to roofs and the like
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Solution Overview
Problem
Solar panel system installers face challenges such as installation complexity, high material costs, and logistical issues due to the need for different clamps for various solar panel frames, which complicates the use of solar panel bottom clamps.
Innovation Solution
A universal solar panel bottom clamp design that can be preinstalled on mounting rails, featuring a lower body that slides within a rail slot, an upper body that secures the return flange, and optional second fasteners for electrical grounding, allowing for easy installation across a range of standard solar panel frames.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If traditional solar panel bottom clamps are used for different solar panel frames, then each specific frame type can be securely mounted, but installation complexity increases and material costs rise due to needing multiple clamp variants
Solution Approach 1:
The clamp body is designed with a universal geometry that can accommodate multiple solar panel frame types through a single clamp design. The lower body fits various rail configurations while the upper body can secure different panel frame styles, eliminating the need for multiple specialized clamp variants and reducing both installation complexity and material costs.
Solution Approach 2:
The clamp is divided into distinct functional segments: a lower body that interfaces with the mounting rail and an upper body that secures the panel frame. This segmentation allows each part to be optimized independently while maintaining overall versatility, enabling the same clamp body to work with different frame configurations through adjustable or adaptable connection mechanisms.
2Adaptability or versatility
If multiple different clamps are stocked for various solar panel frames, then all frame types can be accommodated, but logistical challenges increase and installation time is lost due to missing parts
Solution Approach 1:
By implementing a universal clamp design that can securely mount multiple solar panel frame types, the system eliminates the need to stock multiple specialized clamp variants. Installers can use a single clamp type for all standard frame configurations, ensuring all necessary parts are available and preventing installation delays caused by missing specialized components.
Solution Approach 2:
The clamp design incorporates pre-configured features such as standardized rail engagement mechanisms and adjustable securing elements that are prepared in advance during manufacturing. This preliminary configuration ensures immediate compatibility with various frame types upon installation, eliminating the need for on-site adaptation or search for specific clamp variants.
3Device complexity
If a simplified clamp design with fewer parts is used, then installation becomes easier and material costs decrease, but adaptability to different solar panel frames may be reduced
Solution Approach 1:
The simplified clamp design achieves versatility through a universal clamp body geometry that can interface with multiple rail and frame configurations. Rather than using multiple specialized components, the single standardized clamp body incorporates adaptive features that allow it to securely mount different solar panel frame types, maintaining adaptability while reducing part count and simplifying the overall assembly.
Data Source
AI summary
A solar panel bottom clamp assembly that secures the underside of a solar panel frame (i.e., the return flange of the solar panel) to a mounting rail. The mounting rail being securable to a mounting surface such as a roof. The solar panel bottom clamp assembly includes a solar panel bottom clamp and a threaded fastener. The solar panel bottom clamp includes a lower body and an upper body. The lower body is slidable within a slot positioned lengthwise along the side of the mounting rail. The upper body extends from the lower body and over the return flange. The threaded fastener being threadable diagonally through the lower body, secures the solar panel to the mounting rail by impinging against the slot which pushes the lower body downward and the upper body against the return flange.