Solar Module Cable Flange for Durable Cable Retention
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Solution Overview
Problem
Existing cable management systems for solar modules are inefficient, relying on zip ties and metal clips that wear out quickly and are costly, and pose ergonomic challenges during installation due to sharp edges and heavy weight, increasing the risk of accidents and installation difficulties.
Innovation Solution
A cable management system with a flexible cable management flange integrated into the solar module frame, providing a secure and durable cable cavity that eliminates the need for additional cable management implements and enhances ergonomics by reducing hand fatigue through rounded edges and additional grip features.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If zip ties and metal clips are used to secure cables to the module frame, then cable management is achieved, but the cable management system wears out quickly and becomes costly
Solution Approach 1:
The patent combines the cable management function directly into the module frame structure by integrating a cable management flange with cable retention features. This eliminates the need for separate zip ties and metal clips, creating a unified structure that provides both frame support and cable management functions, thereby improving durability while reducing system complexity
Solution Approach 2:
The module frame is designed to serve multiple functions: structural support, cable management, and cable retention. The cable management flange integrated into the frame provides universal functionality by handling both the mechanical support of the frame and the organization/securing of cables, eliminating the need for dedicated cable management components
2Reliability
If additional cable management implements are used, then cable security is improved, but material needs and installation complexity increase
Solution Approach 1:
The cable management flange is integrated directly into the module frame structure, combining what would traditionally be separate components (frame and cable management elements) into a single unified structure. This eliminates the need for additional standalone cable management implements while maintaining secure cable retention
Solution Approach 2:
The module frame structure itself provides the cable management function through its integrated flange design. The frame serves its own cable management needs without requiring external cable management implements, reducing material quantity while maintaining cable security
3Ease of manufacture
If standard frames with sharp 90° edges are used, then manufacturing is simplified, but ergonomics deteriorate and hand fatigue increases
Solution Approach 1:
The patent applies curvature to the frame edges by providing rounded edges instead of sharp 90° angles. This maintains manufacturing simplicity while significantly improving ergonomics during handling and installation, reducing hand fatigue and the risk of workplace accidents
4Stability of the object's composition
If the cable management flange is rigid, then structural stability is improved, but flexibility to accommodate cables is reduced
Solution Approach 1:
The cable management flange is designed with non-uniform properties: the root portion near the frame body maintains rigidity for structural stability, while the distal portion becomes more flexible to accommodate and secure cables. This local variation in stiffness allows the flange to provide both structural support and cable adaptability
Data Source
AI summary
A cable management system for managing cables associated with an array of solar modules includes a body having an interior surface extending vertically, a lower flange extending directly from the interior surface of the body, and a cable management flange extending directly from the interior surface of the body above the lower flange. The cable management flange and the lower flange define a cable cavity therebetween for retaining at least one cable. Distal ends of the lower flange and the cable management flange define an opening for inserting the at least one cable into the cable cavity. The cable management flange is arranged to engage the at least one cable and secure the at least one cable in the cable cavity. The cable management flange is flexible to accept and retain the at least one cable.