Snap-In Photovoltaic Frame Fastener for Secure Rail Mounting
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Solution Overview
Problem
Traditional photovoltaic panel mounting systems are complex, time-consuming, and costly to install, with many loose parts and high labor expenses, and are vulnerable to theft and vandalism.
Innovation Solution
A one-piece photovoltaic frame fastener with a U-shaped channel, snap-in clip, flexible wings, and bifurcated tongue design that allows for pre-assembly, secure attachment, and easy installation and removal, while hiding securing elements to deter theft.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional threaded fasteners and multi-piece brackets are used, then secure attachment is achieved, but device complexity and installation time increase significantly
Solution Approach 1:
The patent combines multiple separate components (bracket, fastener, and mounting elements) into a single integrated one-piece fastener structure. This unified design eliminates the need for multiple loose parts while maintaining secure attachment functionality through integrated mounting brackets and fastening mechanisms.
Solution Approach 2:
The one-piece fastener structure performs multiple functions simultaneously: it provides structural support through integrated mounting brackets, secures the photovoltaic module through built-in fastening mechanisms, and simplifies installation by combining all necessary components into a single unit that can be pre-assembled offsite.
2Reliability
If traditional multi-piece brackets with threaded fasteners are used, then secure mounting is achieved, but installation time and labor cost increase
Solution Approach 1:
The one-piece fastener structure allows for pre-assembly of mounting brackets and fastening components offsite or at the manufacturing plant before delivery to the installation site. This preliminary assembly eliminates time-consuming on-site assembly operations and reduces labor requirements during actual installation.
3Ease of operation
If visible securing elements are used, then attachment function is clear, but vulnerability to theft and vandalism increases
Solution Approach 1:
The patent extracts or removes visible securing elements from the exterior view by designing the one-piece fastener structure so that mounting brackets and fastening mechanisms are concealed or integrated into the overall structure, making them invisible or indistinguishable from the normal appearance of the photovoltaic module assembly, thereby reducing targets for theft and vandalism.
4Ease of operation
If snap-in wings are positioned away from the slot, then installation is easier, but torsion stress on the fastener increases
Solution Approach 1:
The patent applies local quality by positioning the snap-in wings in direct alignment with the frame receiving slot at the critical location where insertion occurs. This localized positioning ensures that insertion forces are applied directly along the slot axis, minimizing torsion stress at the most stressed point while maintaining ease of installation through the snap-in mechanism.
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 reduces installation time and cost, enhances security, and minimizes stress on the fastener and panel, providing a more secure and cost-effective attachment method that prevents over-insertion and tilting, while hiding the securing elements to deter theft.
Implementation Method 1
at least one flexible wing matable with an opening in a strut
Implementation Method 2
a flexible tongue internally projecting in a central manner from a top wall of a body
Data Source
AI summary
A photovoltaic frame fastener is provided. In one aspect, a photovoltaic frame attachment apparatus includes a strut or rail defining a generally U-shaped channel and a snap-in clip or fastener. In another aspect, a single-piece fastener includes a strut-engaging surface, at least one flexible wing matable with an opening in a strut, a flexible tongue internally projecting in a central manner from a top wall of a body, and a slot adapted to receive a portion of a photovoltaic panel frame. Yet another aspect of a photovoltaic frame fastener includes laterally projecting tabs abutting against a top of a strut.