Solar Module Coupling Clamp for Faster Row-to-Row Installation
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Solution Overview
Problem
Existing solar module clamps are difficult to secure and do not effectively connect adjacent solar modules, leading to inefficient installation processes.
Innovation Solution
A coupling clamp design featuring a top clamp and a bottom clamp with lateral flanges and a fastener system that securely engages with solar modules, allowing for easy installation and connection between rows.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If traditional clamps are used to connect solar modules, then connection between modules is achieved, but the clamps are difficult to secure and installation is inefficient
Solution Approach 1:
The clamp is divided into two separate components: a U-shaped clamp body and a separate fastening mechanism. This segmentation allows the clamp body to be easily positioned around the solar module and rail, while the fastening mechanism can be independently secured, simplifying the overall installation process and improving both ease of operation and productivity
Solution Approach 2:
The clamp body is designed with pre-formed engagement features including U-shaped geometry that naturally fits around the rail and module frame, and pre-positioned flanges with built-in engagement surfaces. This preliminary configuration eliminates the need for complex assembly steps during installation, allowing workers to simply position and secure the clamp rather than assemble multiple components on-site
2Ease of operation
If solar modules are installed on rails without effective connection, then installation is simple, but modules do not connect to one another between rows
Solution Approach 1:
The clamp merges three functions into a single integrated component: (1) securing the solar module to the rail through the U-shaped body, (2) connecting adjacent modules through lateral flange engagement, and (3) providing structural support through the rigid framework. This merging ensures reliable module-to-module connection while maintaining installation simplicity
Solution Approach 2:
The lateral flanges act as intermediary elements that bridge adjacent solar modules. These flanges extend outward from the clamp body and engage with corresponding features on neighboring modules, creating a continuous connection between modules while the clamp body itself remains the primary intermediary between the module and rail system
Data Source
AI summary
A coupling clamp is provided that includes a top clamp and a bottom clamp. The top clamp may include a top vertical flange and a top lateral flange. The bottom clamp may include a bottom vertical flange and one or more bottom lateral flanges that extend laterally in opposite directions. At least one of the bottom lateral flanges may include a first portion having a surface configured to engage with a solar module and a second portion connected to the bottom vertical flange at an intersection below the surface of the first portion. The coupling clamp may be installed onto one or more solar modules that are positioned onto a rail that has an installed rail clamp. Another solar module may be positioned on the coupling clamp and rail and then slid under the rail clamp, which may be tightened to secure the other solar module to the rail.