Snap-On Structural Connector for Tool-Free Solar Mounting
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Solution Overview
Problem
Current connectors for solar panel mounting systems require physical force and additional hardware or tools for installation, making the process laborious and time-consuming, and they often lack versatility in structural shapes to accommodate various applications.
Innovation Solution
A connector design featuring a unitary construction with ridges and flanges that allows for easy attachment to structural members without additional fasteners or tools, providing a secure and reusable connection capable of withstanding high forces, and adaptable to various structural shapes and applications.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional connectors use additional hardware or fasteners (nuts, bolts, rods, screws), then the connection strength and reliability are improved, but the installation complexity and time consumption increase significantly
Solution Approach 1:
The connector integrates multiple functions into a single unitary structure that combines the mounting plate, fastening mechanism, and structural support elements. This eliminates the need for separate nuts, bolts, and washers, reducing installation complexity while maintaining connection strength through the integrated snap-fit and mechanical interlocking features
Solution Approach 2:
The connector is designed with self-aligning features and snap-fit mechanisms that automatically position and secure structural members without requiring manual manipulation of multiple fasteners. The installer simply needs to position the member, and the connector's geometric features guide and lock it into place, reducing the skill level and time required for installation
2Ease of operation
If connectors are designed for simple installation without tools, then the ease of operation is improved, but the force resistance and structural strength may be compromised
Solution Approach 1:
The connector incorporates flexible elements and resilient features that allow dynamic adjustment during installation but provide rigid, high-strength connection when assembled. The snap-fit mechanisms and spring-loaded components enable tool-free installation while maintaining the force resistance needed to withstand wind loads and structural stresses
Solution Approach 2:
The connector utilizes composite construction combining rigid materials for structural strength with flexible or resilient materials for the snap-fit and locking features. This allows the same component to provide both easy tool-free installation and high force resistance, as the different material properties complement each other in their respective functions
3Ease of manufacture
If connectors are designed as unitary construction for simplicity, then the ease of manufacture and assembly are improved, but the adaptability to various structural shapes is reduced
Solution Approach 1:
The unitary connector is designed with universal geometric features and adjustable elements that allow it to accommodate multiple structural member shapes and sizes. The standardized interface and modular design enable the same connector type to be used across different applications, maintaining manufacturing simplicity while achieving versatility through intelligent geometric design rather than multiple specialized components
Data Source
AI summary
A connector is provided and includes a first and second side wall that are connected by a base. The side walls have recesses such that a structural member's protrusions can be interposed between the side wall's recesses and snapped into place to connect the connector to the structural member.