Reusable Module Stack Holders for Vertical and Horizontal Solar Panels
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Solution Overview
Problem
Existing solutions for stacking and transporting photovoltaic or solar thermal flat modules are inefficient, as they require extensive packaging, are not reusable, and cannot handle both horizontal and vertical stacking forms securely, especially during the hardening phase of the adhesive process.
Innovation Solution
A material-sparing, reusable stack holding system composed of molded plastic parts that connect via mechanical cogging to form stable pillars or rails, allowing for secure horizontal and vertical stacking by engaging with the module frames using resilient fingers and tooth engagement mechanisms, ensuring secure transport and storage without additional packaging.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional packaging methods are used for module stacking and transport, then modules are protected during transport, but extensive packaging materials are required and the system is not reusable
Solution Approach 1:
The holding system is divided into multiple individual molded parts that can be separately attached to module frames and then assembled together to form stacking structures. Each part can be independently reused across multiple stacking and transport cycles, eliminating the need for disposable packaging materials while maintaining module protection.
Solution Approach 2:
The invention implements a reusable holding system where molded parts are attached to module frames during production and then recovered and reused across multiple transport cycles. This replaces traditional single-use packaging with a durable system that can be discarded and recovered for repeated use, significantly reducing material consumption.
2Productivity
If modules are stacked horizontally during the hardening phase, then storage space is optimized, but the adhesive bonding may be compromised without proper contact pressure
Solution Approach 1:
The holding system is attached to module frames before the adhesive hardening process begins. The molded parts are pre-positioned to provide the necessary contact pressure and structural support during the hardening phase, ensuring proper bonding while enabling immediate stacking and storage optimization.
Solution Approach 2:
The molded holding parts act as intermediaries between module frames, providing the necessary mechanical support and contact pressure during adhesive hardening. These intermediaries enable horizontal stacking during the hardening phase while maintaining the required bonding conditions, bridging the gap between storage efficiency and bonding quality.
3Loss of substance
If a reusable holding system is implemented, then material usage is reduced and reuse cycles increase, but the initial attachment process becomes more complex
Solution Approach 1:
The molded parts are designed to be self-attaching to module frames through integrated attachment mechanisms. The parts automatically secure to the frames during the stacking process without requiring separate attachment tools or complex procedures, simplifying the overall process while enabling reusable material efficiency.
Solution Approach 2:
The holding system combines the attachment function and the stacking function into a single integrated molded part. This merging of functions eliminates the need for separate attachment mechanisms and simplifies the overall process, reducing complexity while maintaining material efficiency and reusability.
4Weight of moving object
If molded parts are made small and light for easy return shipment, then transport cost is reduced, but their load-bearing capacity may be insufficient
Solution Approach 1:
The molded parts are manufactured using high-strength, lightweight composite materials or optimized plastic formulations that provide maximum load-bearing capacity relative to their weight. This enables the parts to be light enough for economical return shipment while maintaining sufficient strength to support stacked modules during transport and storage operations.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The system enables efficient, economical storage and transport of modules by allowing stacking during the hardening phase, reducing material usage, and facilitating multiple reuse cycles while ensuring secure handling and transport, even when modules are tilted or turned, thus minimizing waste and logistical complexities.
Implementation Method 1
at least one resilient finger (11) comprising a locking device for engaging with the profile of the module frame
Implementation Method 2
The individual elements of the reusable holding system should be designed as being molded parts, which are as small, handy and light as possible, so as not to complicate their return shipment from the customer to the manufacturer. The molded parts should be capable of being stressed to a high degree, because the total stress of the modules stacked on top of one another must be accommodated by the holding system and transferred onto the pallet at least in the case of the horizontal stacking.
Data Source
AI summary
A material-sparing, reusable stack holding system for supporting and transporting framed photovoltaic or solar thermal flat modules.The system consists of individual molded parts, which form stable and transport-safe pillars or rails, respectively, among one another by means of mechanical cogging and with the frames of the modules by means of a locking connection. To date, only stack holders, in the case of which the solar modules are stacked in horizontal position with the use side facing up (“sunny side”), were known.The system disclosed here makes it possible to stack the modules in horizontal as well as in vertical position. In the case of horizontal stacking, the use side can be arranged facing up or down.