Solar Module Brace for Tilt-Hook Replacement Access
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing solar module mounting systems require excessive components and labor for installation and replacement, especially on sloped roofs, as they necessitate disassembling adjacent modules to remove or replace a damaged module, and use tools that are difficult to align due to their design.
Innovation Solution
A height-adjustable roof anchor system with upwardly facing fasteners and a mechanism allowing solar modules to be removed without sliding adjacent modules, featuring a base with a hole and a height adjustment member with an annular groove for rotational adjustment, and a brace system that supports solar modules for easy disconnection and reinstallation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of repair
If solar modules are mounted using conventional rail systems, then the array can be installed on various roof types, but individual modules cannot be removed without disassembling adjacent modules
Solution Approach 1:
The mounting system is divided into independent modular components: roof anchors, braces, and interlock mechanisms. Each solar module can be independently attached and detached from its supporting structure without affecting adjacent modules, enabling individual replacement while maintaining overall array integrity.
Solution Approach 2:
The system employs dynamic fastening mechanisms that allow for easy assembly and disassembly. The interlock features and quick-connect mechanisms enable modules to be rapidly attached and removed, transforming the static mounting system into a dynamic one that facilitates maintenance and replacement operations.
2Ease of operation
If conventional splicing interlocks are used to connect adjacent modules, then modules can be securely attached, but tool alignment becomes difficult due to horizontal engagement faces requiring special tools
Solution Approach 1:
Instead of using horizontal engagement faces that require lateral tool insertion, the invention inverts the engagement orientation to vertical. The upwardly facing fastener engagement surfaces allow tools to approach from above, aligning with the natural working position of installers and eliminating the need for specialized horizontally-oriented tools.
Solution Approach 2:
The fastener system is designed to be self-aligning and self-servicing. The upwardly facing engagement portions naturally guide tool insertion, and the modular design allows standard tools to automatically align with the correct engagement point, reducing the skill level and specialized equipment needed for installation and maintenance.
3Reliability
If excessive components are used in mounting systems, then reliable anchoring is achieved, but installation and maintenance require excessive labor
Solution Approach 1:
The invention merges multiple functions into integrated components. The braces simultaneously provide structural support, module positioning, and attachment points for interlocks. The roof anchors combine mounting functionality with adjustment capabilities, reducing the total number of separate components needed while maintaining reliable anchoring.
Solution Approach 2:
The mounting components are designed with multi-functionality. The braces serve as both structural supports and alignment guides. The interlock mechanisms provide both mechanical connection and positioning functions. This universality allows a reduced component set to achieve reliable anchoring while simplifying installation procedures and reducing labor requirements.
Data Source
AI summary
A brace for connecting the frames of adjacent solar modules can include one or more lower lips and one or more upper lips configured to capture an outer edge of a solar module frame. The brace can include a removable top so as to facilitate connection and disconnection of the couplers and solar modules. Additionally, the brace can be configured to allow a solar module to be engaged and disengaged by hooking the frame onto the brace then tilting the frame relative to the brace. The brace can include features for achieving a snap fit with solar module frames.