Single-Piece Solar Module Clamp for Secure Tool-Free Mounting
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Solution Overview
Problem
Existing solar panel mounting systems face challenges in being both secure and easy to install, particularly in utility-scale solar power plants, where they need to be rugged and quick to assemble.
Innovation Solution
A photovoltaic module clamp with a unitary single-piece structure featuring a web, sidewalls, and a bendable projection that secures the panel to a structural support surface, allowing for easy installation without tools.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional multi-component mounting systems are used, then structural strength and reliability are improved, but device complexity and installation time increase
Solution Approach 1:
The patent combines multiple mounting components (side walls, web, flanges, and fastening elements) into a single integrated clamp structure. This unification maintains the structural strength and reliability of traditional multi-component systems while eliminating the complexity of assembling multiple separate parts, directly resolving the technical contradiction between mounting security and system complexity.
2Reliability
If traditional multi-step installation methods are used, then mounting security is improved, but installation time and productivity decrease
Solution Approach 1:
The clamp is pre-configured with the web positioned between the side walls and the flanges formed in advance on the side walls. This preliminary arrangement of all mounting elements in the correct positions before installation allows the entire clamp to be quickly attached to the solar panel and mounting surface in a single operation, maintaining mounting security while dramatically improving installation speed and productivity.
3Ease of operation
If simplified single-piece clamps are used, then ease of installation is improved, but structural strength and reliability may decrease
Solution Approach 1:
The single-piece clamp incorporates locally optimized features including reinforced web structures between the side walls, strategically positioned flanges with specific geometries, and enhanced fastening elements. These localized quality improvements ensure that the simplified single-piece design maintains adequate structural strength and reliability while achieving ease of installation.
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
The clamp provides secure and efficient mounting of solar panels by allowing for quick and tool-free installation, enhancing ease and speed of assembly.
Implementation Method 1
A bendable projection extends from the first sidewall through the through hole and into the cavity
Data Source
AI summary
A photovoltaic module clamp that secures a photovoltaic module to a structural support surface comprises a web that separates a first sidewall and a second sidewall at a distal end of the clamp, where the first and second sidewalls are substantially opposing and spaced apart to form a cavity. The web includes a plurality of segments includes a plurality of radiused segments and first and second opposing gussets located on respective opposing ones of the plurality of radiused segments. The first sidewall includes a through hole that receives a projection extending from the structural support surface. The second sidewall includes a rib extending from a proximate end of the second sidewall towards the distal end of the clamp, and the proximate end of the second sidewall flares outwardly from the cavity. The first sidewall has a first sidewall length extending along the first sidewall between the proximate and distal ends that is greater than a second sidewall length of the second sidewall extending along the second sidewall between the proximate and distal ends. A bendable projection extends from the first sidewall through the through hole and into the cavity.