Flexible Solar Collector Clips for Fast Precise Array Alignment

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Solution Overview

Problem

The inefficiencies in the manufacturing process of solar arrays due to the need for precise angular alignment of solar collectors, which is currently achieved through shimming or additional hardware, result in increased complexity and cost, as well as reduced efficiency and longer assembly times.

Innovation Solution

A flexible attachment device, comprising a collector-engaging portion, a biasing portion, and frame-engaging portions with guide flanges, is used to attach solar collectors to a structural framework, allowing for precise alignment and flexible adjustment to accommodate manufacturing tolerances without the need for additional hardware or shimming.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If solid or liquid shims are used to adjust alignment, then manufacturing precision is improved, but manufacturing time and productivity are reduced

Engineering Contradiction:
Improvealignment precisionVSAvoidassembly efficiency
Core Design Contradiction:
Manufacturing precisionVSProductivity

Solution Approach 1:

The patent removes the shim component entirely from the assembly process. Instead of adding shims to adjust alignment, the connecting hardware itself is designed with built-in adjustment capability through its geometry and flexibility, allowing direct attachment without intermediate alignment components.

Inventive Principle:
Principle #2Taking out (Extraction)

Solution Approach 2:

The patent combines the alignment adjustment function with the connecting hardware function. The single component performs both structural connection and angular adjustment, eliminating the need for separate shim components and reducing the number of assembly steps.

Inventive Principle:
Principle #5Merging (Combining)

2Manufacturing precision

If additional connecting hardware is used to adjust collector angle, then manufacturing precision is improved, but device complexity and cost increase

Engineering Contradiction:
Improveangular alignmentVSAvoidhardware complexity
Core Design Contradiction:
Manufacturing precisionVSDevice complexity

Solution Approach 1:

The connecting hardware is designed as a multi-functional component that simultaneously provides structural support, angular adjustment, and mechanical connection. This universal design eliminates the need for multiple specialized components (shims, adjustment mechanisms, additional fasteners) and reduces overall system complexity.

Inventive Principle:
Principle #6Universality (Multi-functionality)

Solution Approach 2:

The patent employs a flexible connecting hardware design that can bend or flex to accommodate angular variations. This flexibility allows the single component to adapt to different alignment requirements without requiring complex mechanical adjustment mechanisms or multiple rigid parts.

Inventive Principle:
Principle #30Flexible shells and thin films

3Manufacturing precision

If traditional shimming process is used, then alignment precision is improved, but manufacturing time and cost increase

Engineering Contradiction:
Improvecollector alignmentVSAvoidassembly time
Core Design Contradiction:
Manufacturing precisionVSLoss of time

Solution Approach 1:

The connecting hardware is pre-designed with built-in alignment capabilities and geometric features that automatically compensate for tolerances during assembly. This preliminary design eliminates the need for time-consuming measurement, calculation, and application of shims during the assembly process.

Inventive Principle:
Principle #10Preliminary action

Solution Approach 2:

The connecting hardware performs self-alignment through its geometric design and flexibility, automatically accommodating tolerance variations without requiring external adjustment tools or procedures. The component serves its own alignment function, eliminating the need for operator intervention in the shimming process.

Inventive Principle:
Principle #25Self-service

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

This solution enables a more efficient and cost-effective manufacturing process by allowing for precise alignment of solar collectors with reduced complexity and assembly time, while maintaining the structural integrity and efficiency of the solar array.

Implementation Method 1

a biasing portion configured to allow the flexible attachment device to flex inward towards the solar collector during assembly

Methodology Applied
Scientific EffectElasticity: Elasticity

Data Source

PatentUS8677701B2Attaching solar collectors to a structural framework utilizing a flexible clip
Publication Date: 2014.03.25 THE BOEING CO
  • US8677701B2 patent drawing
  • US8677701B2 patent drawing
  • US8677701B2 patent drawing

AI summary

Methods and apparatuses described herein provide for the attachment of solar collectors to a structural framework in a solar array assembly. A flexible clip is attached to either end of each solar collector and utilized to attach the solar collector to the structural framework. The solar collectors are positioned to allow a member of the framework to engage a pair of flexible clips attached to adjacent solar collectors during assembly of the solar array. Each flexible clip may have multiple frame-engaging portions, each with a flange on one end to cause the flexible clip to deflect inward when engaged by the framework member during assembly and to guide each of the frame-engaging portions into contact with a surface of the framework member for attachment.