Solar Module Frame Assembly Using Screwless Interlocking Supports
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Solution Overview
Problem
The installation of solar modules is inefficient due to the complexity of tools and procedures required, particularly in fixing them onto frames, which hinders assembly speed and efficiency.
Innovation Solution
A frame system for solar modules featuring a bar base with positioning holes and supports that interlock without the need for screws, utilizing angled extension portions and recesses to securely engage the supports, reducing the number of assembly steps and enhancing structural strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional screw-based fixation methods are used for solar modules, then structural strength is ensured, but assembly complexity and time increase
Solution Approach 1:
The patent removes the screw-based fixation system from the assembly process. Instead of using traditional screws and bolts to secure solar modules to the frame, the invention extracts this complex fastening mechanism and replaces it with a simplified slot-based insertion system where modules slide directly into positioning slots on the frame rails.
Solution Approach 2:
The frame is segmented into modular components with standardized slots and positioning features. The solar module mounting system is divided into separate frame rails and module units that can be independently assembled and connected through the slot mechanism, enabling rapid assembly without complex fastening procedures.
2Reliability
If traditional screw-based fixation methods are used for solar modules, then secure fixation is achieved, but assembly time increases
Solution Approach 1:
The frame rails are pre-equipped with positioning slots and engagement features during manufacturing. These slots are precisely positioned and dimensioned in advance to receive and secure the solar module mounting brackets, eliminating the need for on-site measurement, drilling, and screw installation while ensuring reliable fixation.
3Ease of manufacture
If standardized frame structures are used for solar modules, then manufacturing efficiency is improved, but positioning flexibility is reduced
Solution Approach 1:
The patent introduces adjustable positioning mechanisms that operate in multiple dimensions. The solar modules can be positioned along the length of the frame rails using movable clamps or adjustable brackets that slide along the rails, providing flexibility in both the longitudinal and lateral dimensions while maintaining the simplicity of the standardized frame structure.
Data Source
AI summary
A frame for supporting a solar module is disclosed. The frame includes a bar base and a first support. The bar base has at least two positioning holes. The first support is utilized for being engaged with the bar base. The first support includes two first sidewalls, two first extension portions, and a first top plate. Each of the first sidewalls has a first opening. Each of the first extension portions extends from an edge of the corresponding first opening toward an interior of the first support. An angle is included between each of the first extension portions and the corresponding first sidewall. The first top plate is disposed on top of the first sidewalls. Each of the first extension portions is trapped in the corresponding positioning hole when the first support is engaged with the bar base.