Solar array column cap
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Solution Overview
Problem
Existing column caps for solar arrays are inefficient due to excessive material usage, deformation under load, high installation costs, and incompatibility with horizontal beams of non-circular cross sections, limiting their effectiveness and versatility.
Innovation Solution
A solar array column cap design featuring a main body with radial flanges and co-planar upper flaps configured to receive a U-bolt, allowing secure attachment of horizontal beams with various cross sections, fabricated using metal stamping and bending processes to reduce material waste and installation complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If existing column caps are made from steel or aluminum with traditional casting methods, then structural strength is achieved, but material usage is excessive and manufacturing cost increases
Solution Approach 1:
The patent changes the manufacturing method from traditional casting to metal stamping and bending processes. This parameter change in fabrication technique allows for more efficient material utilization while maintaining the required structural strength of the column cap
Solution Approach 2:
The column cap design incorporates varying material distribution and thickness in different regions, optimizing material usage where structural strength is most needed while reducing material in areas with lower load requirements
2Ease of operation
If existing column caps are designed for circular cross section beams, then attachment is simplified, but adaptability to rectangular or square cross section beams is lost
Solution Approach 1:
The column cap is designed with a universal interface that can accommodate both circular and rectangular/square cross section horizontal beams. The main body structure and flange configuration allow the same component to function with multiple beam types, eliminating the need for different cap designs
3Reliability
If existing column caps use traditional casting and machining methods, then structural integrity is maintained, but installation complexity and cost increase
Solution Approach 1:
The patent replaces traditional casting and machining processes with metal stamping and bending operations. This substitution simplifies manufacturing while maintaining structural integrity through controlled forming processes that preserve material properties and create reliable structural features
4Force
If existing column caps are designed with traditional configurations, then structural support is provided, but deformation under loading occurs
Solution Approach 1:
The column cap is divided into distinct functional segments including the main body, radial flanges, and co-planar upper flaps. This segmentation allows each component to be optimized for its specific function while working together to distribute and resist applied loads, preventing deformation
Data Source
AI summary
Disclosed herein is a solar array column cap that includes a main body extending between a left side and a right side to define a channel, the channel configured to at least partially receive a vertical column of a solar array support structure such that the main body surrounds the vertical column. The main body further includes a left flange extending radially outwardly from the left side of the channel and right flange extending radially outwardly from the right side of the channel. Further, the main body includes an left upper flap extending from a top edge of the left flange, and a right upper flap extending from a top edge of the right flange, the right upper flap and left upper flap being co-planar. In another embodiment, a body has an opening extending along a center axis from a bottom to a top, the opening configured to receive the vertical column such that the body surrounds the vertical column, and an upper support surface configured to receive a horizontal beam, the upper support surface being located in a plane that is non-perpendicular with the center axis.