Solar Module with Preassembled Mount to Reduce Installation Complexity
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Solution Overview
Problem
Existing solar module installation methods require complex and time-consuming processes, involving multiple components and precise layout, which increases labor, material costs, and reduces installation efficiency and flexibility.
Innovation Solution
A preassembled solar module design with integrated mounting structures, including electrically insulating feet and a leveling mechanism, allows for secure and flexible mounting directly to a structure surface without additional fasteners, simplifying the installation process and enabling easy adjustment and replacement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional solar module installation methods are used with separate racks and multiple components, then the solar modules can be securely mounted on the structure surface, but the installation process becomes complex and time-consuming with increased labor and material costs
Solution Approach 1:
The patent combines the mounting structure and solar module into a single integrated assembly. The mount is pre-connected to the solar module frame, merging previously separate components (rack, clamps, fasteners, and module) into one unified unit that simplifies installation while maintaining secure mounting capability
Solution Approach 2:
The integrated mount structure serves multiple functions simultaneously: it provides structural support, enables secure attachment to the rafter system through interlocking mechanisms, and incorporates leveling adjustments. This multi-functional design eliminates the need for separate mounting components
2Manufacturing precision
If traditional installation methods with precise layout requirements are used, then the solar modules can be properly positioned on the structure surface, but the installation time and labor requirements increase
Solution Approach 1:
The mount is pre-assembled and pre-positioned relative to the solar module during manufacturing. This preliminary action establishes precise positioning geometry before installation, eliminating the need for time-consuming on-site measurements and adjustments while maintaining accurate module placement
Solution Approach 2:
The mounting system is divided into modular segments with standardized connection interfaces. This segmentation allows for quick assembly and positioning without requiring complex layout calculations, as each module can be independently positioned and connected to the rafter system
3Reliability
If additional fasteners and mounting components are used, then the solar modules can be securely attached to the structure surface, but the material costs and installation complexity increase
Solution Approach 1:
The mounting structure integrates multiple attachment functions into a single component assembly. The mount incorporates built-in fastening mechanisms that directly engage with the rafter system, eliminating the need for separate clamps, brackets, and multiple fastener types
Solution Approach 2:
The mount structure includes self-retaining features such as spring-loaded locking mechanisms and interlocking geometries that automatically secure the solar module to the rafters without requiring additional fasteners or complex assembly steps
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 solution simplifies the installation of solar modules by reducing labor and material requirements, enhancing positional flexibility, and improving installation efficiency while maintaining structural integrity and energy generation performance.
Implementation Method 1
a solar module for installation on a structure includes a solar laminate for converting solar energy into electricity
Data Source
AI summary
A solar module for installation on a structure includes a laminate for converting solar energy into electricity. The solar module also includes a mount releasably connected to the laminate for mounting the solar module on a surface of the structure. The mount includes openings to receive fasteners for securing the mount to the surface of the structure. The solar module has a pre-mount configuration in which the mount is connected to the laminate as a single unit. The mount is sized to allow the solar module to be shipped in the pre-mount configuration.