Solar Module Connector With Slot Inserts For Rail-Free Mounting
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Solution Overview
Problem
The high installation costs and complexity of solar module systems due to the need for long rails and various-sized clamps to accommodate different frame thicknesses, as well as the difficulty in securely connecting and removing solar modules, especially when not levelled, in rail-less or rail-free mounting methods.
Innovation Solution
The use of interlocking and clamping solar module connectors that slide into slots on the solar module frames, combined with adjustable roof attachments featuring T-bolts and L-brackets, allowing for secure connection and easy removal of solar modules, while also providing electrical bonding and accommodating different roof types.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If long rails are used to secure solar modules, then the solar modules can be securely mounted, but the transportation and material costs increase
Solution Approach 1:
The patent removes the traditional long rail structure from the mounting system and replaces it with individual connectors that attach solar modules directly to the roof structure. This extraction of the rail component eliminates the need for extensive material while maintaining secure mounting capability through direct roof attachment points.
Solution Approach 2:
The mounting system is divided into discrete connector units, each capable of independently securing a solar module to the roof. This segmentation replaces the continuous rail structure with modular components that reduce overall material requirements while providing equivalent or superior securing functionality.
2Adaptability or versatility
If various-sized clamps are used to accommodate different frame thicknesses, then all solar module types can be mounted, but the device complexity increases
Solution Approach 1:
The connector is designed with a universal adjustment mechanism that can accommodate various solar module frame thicknesses using a single component design. The adjustable features allow the same connector to adapt to different module types without requiring multiple specialized clamp sizes, thereby reducing system complexity while maintaining versatility.
Solution Approach 2:
The connector incorporates dynamic adjustment capabilities that allow it to adapt its configuration based on the specific frame thickness being mounted. This dynamic adaptability replaces the need for multiple static clamp sizes with a single versatile component that can be adjusted on-site to fit different module specifications.
3Quantity of substance
If rail-less mounting methods are used, then material costs are reduced, but the difficulty of securely connecting and removing solar modules increases
Solution Approach 1:
The rail-less system uses individually segmented connectors that can be independently attached and detached from each solar module and roof attachment point. This segmentation enables easy connection by simply assembling the connector components and secure removal by disassembling the same components, maintaining operational ease without requiring long rails.
Solution Approach 2:
The connector is pre-configured with integrated features for both secure attachment and easy release mechanisms. The preliminary design incorporates quick-connect and quick-release capabilities that simplify both installation and maintenance operations, allowing workers to easily connect and remove modules without complex procedures despite the absence of traditional rails.
Data Source
AI summary
A solar module connector connects a first solar module to a second solar module. A solar module connector top part includes a slot insert that fits within a frame slot of a first solar module frame of the first solar module. A solar module connector bottom part includes a slot insert that fits within a frame slot of a second solar module frame of the second solar module. A fastener securely fastens the solar module connector top part to the solar module connector bottom.