Solar Array Framing Layout for Prewired Modular Mounting
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Solution Overview
Problem
Existing solar panel mounting systems often require redundant material due to uniform frame designs, are laborious to install, and can obstruct solar energy collection, with wiring typically done after module securing and requiring access underneath the array.
Innovation Solution
A modular framing system with interconnected frame members, including T-shaped and I-shaped configurations, featuring connectors and mounts to secure solar panels at spaced positions, allowing for efficient installation and reduced material usage, with channeled sections for wiring facilitation and stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If uniform cross-section frames are used for all modules, then construction is simplified, but redundant unnecessary material is created
Solution Approach 1:
The patent applies local quality by differentiating frame designs based on position: end modules receive full-strength frames with complete connector provisions, while intermediate modules use reduced frames with fewer connectors. This localized adaptation eliminates redundant material in intermediate positions while maintaining construction simplicity through standardized components.
Solution Approach 2:
The framing system is segmented into different frame types (end frames and intermediate frames) with distinct structural characteristics. This segmentation allows each frame type to be optimized for its specific functional requirements, reducing overall material usage while maintaining system integrity.
2Device complexity
If modules are suspended by connection to adjacent module frames, then direct support structure is reduced, but frame material must accommodate additional loads
Solution Approach 1:
The patent extracts the support function from a separate structural system and integrates it into the module frames themselves. By incorporating mounting provisions directly into the frame design, the system eliminates the need for additional support structures while using less total material through the optimized frame configurations.
3Ease of manufacture
If wiring is completed after solar laminates are secured, then installation sequence is simplified, but access under the array is required which is laborious
Solution Approach 1:
The patent incorporates wiring channels and access provisions into the frame structure during the framing installation phase. This preliminary action allows wiring to be performed through the frame structure rather than requiring later access from underneath the array, significantly reducing labor time while maintaining installation sequence simplicity.
4Strength
If solar energy directly impacts the frames, then structural support is provided, but solar energy collection is obstructed
Solution Approach 1:
The patent positions the solar collecting devices in a dimension spaced from the frame members, creating vertical separation between the energy collection surface and the structural support element. This dimensional arrangement allows solar energy to reach the collecting devices without being blocked by the frames, while the frames maintain their structural support function.
Data Source
AI summary
A framing system for mounting solar collection devices to form a solar array can include a plurality of interconnected frame members having connectors provided on the frame members to form rows of an array solar collector devices. Mounts can be provided at the upper portion of the frame members to secure the solar collecting devices at a raised position. The framing system can simplify the installation of the wiring system before the solar collection devices are attached to the frame members.