Solar Module Connector Structure for Rail-Less Rooftop Mounting
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Solution Overview
Problem
The existing solar module installation methods are costly and complex due to the need for adjustable rail systems and various-sized clamps to accommodate different frame thicknesses, and the difficulty in precisely positioning solar modules on uneven rooftops, leading to increased installation time and expense.
Innovation Solution
A rail-less solar mounting system using module connectors and brackets that separate solar module connection from roof attachment, allowing for adjustable and secure connections between solar modules and the roof using embedded bolts and hook-shaped components, reducing the number of mounting components and simplifying the installation process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If rail systems are used to secure solar modules, then modules can be stably mounted, but transportation and material costs increase
Solution Approach 1:
The patent removes the rail component from the mounting system entirely, extracting only the essential functions of support and attachment. The module connector directly connects modules to each other and to the roof structure without requiring intermediate rails, thereby eliminating rail-related transportation and material costs while maintaining mounting stability.
Solution Approach 2:
The module connector performs multiple functions: it connects adjacent modules together, attaches modules to the roof structure, and accommodates various frame thicknesses. This multi-functional design replaces the need for separate rails and multiple clamp sizes, reducing overall system complexity and cost.
2Adaptability or versatility
If multiple clamp sizes are used to accommodate different frame thicknesses, then all module types can be secured, but device complexity increases
Solution Approach 1:
The module connector is designed as a universal component that can accommodate solar modules with different frame thicknesses through a single design. The connector structure includes adjustable or adaptable features that allow it to securely hold various frame sizes without requiring multiple specialized clamp variants.
Solution Approach 2:
The connector incorporates dynamic or adjustable elements that allow it to adapt to different frame thicknesses. This may include movable components or adjustable mechanisms within the connector that can be configured to match various module frame dimensions, providing versatility without increasing the number of distinct component types.
3Device complexity
If clamps provide dual functions of connecting modules and securing to roof, then number of components is reduced, but optimal positioning is compromised
Solution Approach 1:
The patent segments the mounting system into distinct functional components: the module connector for connecting modules to each other, and separate roof attachment mechanisms for securing to the roof structure. This segmentation allows each component to be optimized for its specific function, with connectors positioned precisely for module-to-module connection and roof attachments positioned independently for optimal structural support.
Solution Approach 2:
The module connector acts as an intermediary component between the solar modules and the roof attachment system. It provides a dedicated interface for module connection while allowing the roof attachment to focus solely on structural support, enabling both components to achieve optimal positioning for their respective functions without compromise.
4Ease of manufacture
If roof attachments are installed before modules, then roof structure is prepared, but precise positioning becomes difficult
Solution Approach 1:
The module connector and roof attachment system incorporate dynamic or adjustable positioning features that allow for fine-tuning during installation. This enables installers to first secure the general positioning and then make precise adjustments to achieve accurate module alignment, regardless of the installation sequence used.
Data Source
AI summary
A module connector connects a first solar module to a second solar module. A first part of the module connector includes a top component having a top flange that is slightly tilted lower at a tip of the top flange. A bottom component has a hook-shaped end that is shaped to slide and enclose an inner side of a module frame bottom of the first solar module. A first fastener is used to secure the first solar panel module between the top component and the bottom component. A second part of the module connector includes a top component having a top flange that is slightly tilted lower at a tip of the top flange. A bottom component of the second part has a hook-shaped end that is shaped to slide and enclose an inner side of a module frame bottom of the second solar module. A second fastener is used to secure the second solar panel module between the top component and the bottom component of the second part. A third fastener fastens the top component of the first part to the bottom component of the second part.