Solar Module Cable Clip Layout for Twist-Free Cable Routing
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Solution Overview
Problem
Existing solutions for managing solar module cables, such as drilling holes or using multi-piece clips with cable ties, are inefficient and costly, often resulting in sagging or twisted cables during installation.
Innovation Solution
A one-piece cable clip with perpendicular or parallel recessed sections that securely mounts onto the edge of solar modules, allowing cables to run either perpendicular or parallel, reducing sagging and twisting while being cost-effective to manufacture.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If modules are installed as close as possible to save space, then space utilization is improved, but cables sag and twist causing installation problems
Solution Approach 1:
The cable management system is segmented into multiple functional components: a clip member with toothed engagement features for securing to modules, a separate cable receiving portion, and an integrated mounting structure. This segmentation allows each component to be optimized independently while working together to solve the cable management problem in close-spaced installations
Solution Approach 2:
The cable clip acts as an intermediary device between the solar modules and the cables. It provides a mounting structure with recesses that hold cables in a controlled position, preventing sagging and twisting while allowing modules to be installed close together. The intermediary structure transfers the mechanical support function from direct cable routing to a dedicated mounting component
2Ease of operation
If a hole is drilled in the module edge to loop the cable, then cable sagging is reduced, but installation time and work increase
Solution Approach 1:
The cable clip is pre-formed with integrated cable receiving recesses and module engagement features during manufacturing. This preliminary preparation eliminates the need for on-site drilling and cable looping operations, allowing installers to simply attach the pre-configured clip and route cables through the pre-formed recesses, significantly reducing installation time
Solution Approach 2:
The cable clip design incorporates self-aligning features and snap-fit engagement mechanisms that allow the clip to automatically position itself on the module edge without requiring precise drilling or complex alignment procedures. The toothed recesses and engagement features work together to secure the clip in the correct position automatically during installation
3Ease of operation
If a multi-piece clip with cable tie is used, then cable management is improved, but manufacturing cost increases and cables become twisted
Solution Approach 1:
The invention merges multiple previously separate components (clip body, cable tie, mounting structure) into a single integrated one-piece molded component. This consolidation eliminates the need for assembly of multiple parts, reduces manufacturing complexity and cost, while maintaining effective cable management functionality through the integrated design of engagement features and cable receiving recesses
Solution Approach 2:
The one-piece cable clip performs multiple functions simultaneously: it secures to the module edge via toothed engagement, holds cables in controlled positions through integrated recesses, and provides structural support. This multi-functionality replaces what previously required multiple separate components, simplifying both manufacturing and installation while eliminating cable twisting issues
Data Source
AI summary
A cable clip is provided for mounting cables onto solar modules. The cable clip is a one piece assembly that is comprised of two main sections: a first recess for clipping onto a solar module and a second recess for receiving a cable from a solar module. The cable clip may be designed in either a parallel or perpendicular configuration which gives installers of solar modules maximum flexibility when mounting cables onto modules. A multi-level clip is also described for cases when a multitude of cables are required to be mounted onto a solar module.