Single-Piece Hinged Clamp for Simplified Solar Module Mounting
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Solution Overview
Problem
The installation of solar power generation systems is delayed due to the complexity of existing clamp assemblies, which require handling multiple separate components during the installation process.
Innovation Solution
A single-piece hinged-clamp assembly with a flexible hinge, tapered flanges, and notches, along with a spring mechanism, that simplifies the clamping process by reducing the number of parts to handle and provides a snapping indication of secure engagement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If multiple separate components (threaded fastener, nut, two opposing members) are used to provide clamping force, then the clamping function is achieved, but the number of parts to handle increases and installation time increases
Solution Approach 1:
The patent combines multiple separate clamping components (threaded fastener, nut, and two opposing members) into a single integrated clamp assembly. The clamp includes a body with first and second clamping members, a threaded bore, and an aperture, all formed as one piece. This merging eliminates the need to handle multiple separate parts during installation, directly resolving the contradiction by reducing component count while maintaining clamping functionality.
2Productivity
If multiple separate components are used for clamping, then the clamping force can be distributed, but the installation process becomes more complex and time-consuming
Solution Approach 1:
The clamp assembly integrates the threaded fastener, nut, and opposing members into a single monolithic structure. The body includes integrated features such as the threaded bore for receiving fasteners and apertures for positioning, eliminating the need to assemble multiple separate components. This single-piece design directly improves installation speed by reducing the number of parts to handle while maintaining the structural integrity and clamping force distribution.
3Device complexity
If a single-piece clamp is used to reduce parts, then installation time is reduced, but the clamp may lack the flexibility and adjustment capability of multi-component designs
Solution Approach 1:
The clamp assembly incorporates a flexible hinge connecting the first and second clamping members, allowing the clamp to adapt to slight variations in the distance between structural members. This dynamic flexibility is built into the single-piece design, enabling adjustment capability without requiring multiple separate components. The hinge allows the clamp to flex and conform to different spacing requirements while maintaining structural integrity.
4Reliability
If traditional multi-component clamps are used, then adjustment is possible, but there is no positive indication that members are securely clamped
Solution Approach 1:
The clamp assembly includes a snap-fit feature where the first clamping member engages with a corresponding feature on the second clamping member through the flexible hinge. This engagement provides tactile and audible feedback to the installer, confirming that the clamp is properly secured. The snap-fit mechanism serves as built-in feedback, eliminating the need for separate verification steps and ensuring reliable secure engagement while simplifying the installation process.
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 solution significantly reduces installation time by allowing a single-piece hinged-clamp to securely engage structural members with a visual and tactile confirmation of clamping, thereby streamlining the installation process.
Implementation Method 1
a spring
Implementation Method 2
a base with a flexible hinge
Data Source
AI summary
Single-piece hinged-clamps employed used in assemblies used to mount solar power modules to surface installation are disclosed. In some embodiments, a clamp with a right portion with a right notch having a right platform, a left portion with a left notch having a left platform, and a base portion with a flexible hinge is disclosed. The left portion also includes a threaded aperture extending downwardly from the left platform. In some embodiments, a method of securing a component with the clamp is disclosed in which a right member of a component is inserted into a right notch of a clamp, an applied force imparts movement of a left notch away from the right notch, and a buildup of potential energy in the flexible hinge during the application of the force moves the left notch in the opposite direction to engage the left member of the component.