Serrated Clip Assembly for Tool-Free Solar Module Mounting
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Solution Overview
Problem
The assembly of solar modules onto rail systems is inefficient due to the small space for fasteners, requiring time-consuming and costly processes, and existing coupling members are difficult to manufacture and store.
Innovation Solution
The use of clips with serrated edges and locking members that bite into the solar module frames and rail structures, eliminating the need for fasteners by securely gripping the structures without pre-drilled holes, allowing for quick and efficient assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional fasteners and coupling members are used to mount solar modules, then the mounting process can be completed with standard hardware, but the assembly process becomes time-consuming and physically challenging due to limited access space
Solution Approach 1:
The patent combines the coupling member and fastener functions into a single integrated clip assembly. The clip includes integrated features for both coupling the solar module to the rail and fastening the assembly, eliminating the need for separate fasteners and reducing assembly steps while maintaining secure mounting
Solution Approach 2:
The patent extracts the fastening function from separate hardware components and integrates it directly into the clip structure. The serrated edges and locking features are built into the clip itself, removing the need for additional fasteners and simplifying the assembly process
2Reliability
If traditional fasteners and coupling members are used, then standard hardware can be employed, but the assembly process requires precise positioning and multiple simultaneous operations
Solution Approach 1:
The clip assembly is designed to be self-aligning and self-securing. The serrated edges automatically engage with the rail and solar module frame, and the locking features activate through simple compression without requiring precise positioning or multiple simultaneous operations by the assembler
3Reliability
If conventional coupling members and fasteners are used, then standard components can be sourced, but manufacturing and storage costs increase due to multiple separate parts
Solution Approach 1:
The patent merges multiple separate components (coupling member, fastener, and mounting hardware) into a single integrated clip assembly. This reduces the total part count, simplifies manufacturing processes, and lowers both manufacturing and inventory storage costs while maintaining secure mounting functionality
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 clips enable rapid and efficient mounting of solar modules by securely locking them into place without additional fasteners, reducing assembly time and manufacturing costs while maintaining structural integrity.
Implementation Method 1
The clips include at least one serrated edge configured to bite into at least one of the framed solar module, the support rail or mounting structure of the solar power system, or both
Implementation Method 2
The locking member is positioned on the distal end portion of the sidewalls and is configured to extend into the channel when the clip is positioned over the support rail and the framed solar module
Data Source
AI summary
The present disclosure relates to a solar power system including at least one mounting assembly including a rail, at least one framed solar module, and at least one clip to secure the solar module to the rail. The clip includes at least a pair of sidewalls extending from a top plate or rear wall, each sidewall including a slot, a recess, and a locking member, at least one of the slot, recess, or both include a serrated edge. The clips may secure a solar module to the rail by coupling to the frame of the solar module to a rail of the mounting assembly within the slots of the sidewalls. The clips may be secured to the mounting assembly by locking members positioned on a distal end thereof. The clips may establish an electrical grounding connection between the frame of the solar module and the rail.