Snap-In Laminate Solar Panel Mounting for Lower Install Cost

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Solution Overview

Problem

The high costs associated with transporting and installing solar panels are due to the large size and weight of mounted panels, which require multiple shipping containers and a complex installation process involving numerous components and labor, necessitating a more efficient and cost-effective mounting solution.

Innovation Solution

The introduction of a snap-in mounting system using laminate strips that securely attach to solar cell mounting rails, eliminating the need for frames and mounting hardware, and allowing for easy installation without specialized tools, while providing stiffening support and theft deterrence.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If solar panels are mounted on frames with traditional mounting hardware, then structural support and stability are improved, but transportation cost and device complexity increase

Engineering Contradiction:

Improvestructural supportVSAvoidmounting hardware

Core Design Contradiction:

StrengthVSDevice complexity

Solution Approach 1:

The mounting function is merged directly into the solar panel structure through integrated mounting tabs that are part of the panel assembly, eliminating the need for separate frames and mounting hardware components

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The solar panel structure serves multiple functions simultaneously: generating electricity, providing structural support, and enabling mounting through integrated tabs, reducing the need for dedicated separate components

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Strength

If solar panels are mounted on frames, then structural integrity is improved, but transportation efficiency deteriorates

Engineering Contradiction:

Improvestructural integrityVSAvoidpanel size

Core Design Contradiction:

StrengthVSVolume of moving object

Solution Approach 1:

The mounting function is segmented into discrete tabs integrated at the panel edges, allowing the panel to maintain structural integrity while reducing overall volume and eliminating the need for bulky frames

Inventive Principle:

Principle #1Segmentation

3Reliability

If traditional mounting hardware is used, then reliable attachment is achieved, but installation labor and time increase

Engineering Contradiction:

Improveattachment reliabilityVSAvoidinstallation time

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The mounting tabs are pre-integrated into the solar panel structure during manufacturing, so that during installation only a simple snapping action is needed, eliminating multi-step attachment processes

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The complex mechanical fastening system involving multiple hardware components is replaced with a simple snap-fit mechanism that achieves reliable attachment through elastic deformation and geometric interlocking

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

4Reliability

If specialized mounting components are used, then secure installation is achieved, but installation cost increases

Engineering Contradiction:

Improveinstallation securityVSAvoidinstallation cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The mounting functionality is combined with the solar panel itself through integrated tabs, eliminating the need for separate purchased mounting components and reducing installation material costs

Inventive Principle:

Principle #5Merging (Combining)

Data Source

PatentUS8984818B2Snap-in mounting systems for laminate solar panels

Publication Date: 2015.03.24 SUNRUN SOUTH LLC

AI summary

Snap-in mounting systems for laminate solar panels are provided. The laminate solar panels can include laminate strips that can be snapped into mounting rails. The mounting rails may be coupled to racking rails for structural support and may include locking mechanisms for additional support and theft deterrence. An entire system may include a number of racking rails, mounting rails, and solar panels.