Solar Module Mounts With Integrated Spacers for Easier Alignment
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Solution Overview
Problem
Existing solar module installation methods are complex, requiring precise alignment and overlapping mounts, which increases installation time and complexity, especially on uneven surfaces, and often necessitate additional tools and labor for proper positioning and securing.
Innovation Solution
The development of preassembled solar modules with integrated mounts and spacers that allow for asymmetric positioning, eliminating the need for overlapping mounts and enabling easier alignment and securing on uneven surfaces, along with features like leveling devices and preinstalled fasteners for simplified installation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional mounting methods with overlapping mounts are used, then structural stability is improved, but installation complexity and time increase
Solution Approach 1:
The mounting system is divided into separate functional components: a mounting bracket attached to the solar module and a separate mounting surface attachment mechanism. This segmentation allows each component to be optimized independently and simplifies installation by eliminating the need for complex overlapping mount arrangements.
Solution Approach 2:
The mounting bracket is pre-assembled with the solar module during manufacturing, with pre-installed fasteners and alignment features. This preliminary action eliminates the need for complex field assembly and ensures proper positioning before installation on the mounting surface.
2Reliability
If precise alignment and overlapping mounts are required, then mounting security is improved, but installation time and labor requirements increase
Solution Approach 1:
The mounting bracket incorporates asymmetric alignment features and offset fastener positions that naturally guide correct positioning during installation. This asymmetric design eliminates the need for precise manual alignment while ensuring secure mounting through the inherent geometric constraints of the bracket structure.
Solution Approach 2:
The mounting bracket includes self-aligning features such as tapered guide surfaces and snap-fit connections that automatically position the bracket correctly on the mounting surface without requiring external alignment tools or complex adjustment procedures.
3Reliability
If traditional mounting components are used, then secure attachment is achieved, but the number of required components and materials increases
Solution Approach 1:
Multiple mounting functions are merged into a single integrated mounting bracket: attachment to the solar module, positioning alignment, and connection to the mounting surface. This consolidation eliminates the need for separate L-feet, rails, clamps, and other discrete components, reducing both the number of parts and installation complexity.
Solution Approach 2:
The mounting bracket is designed as a universal component that performs multiple functions: structural support, alignment reference, fastener mounting, and electrical grounding. This multi-functionality replaces several specialized components with a single versatile element, reducing material requirements while maintaining attachment security.
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
This solution simplifies the installation process, reduces labor and material requirements, allows for flexible positioning on surfaces, and facilitates quicker assembly of solar arrays, even in challenging locations, while maintaining structural integrity and energy efficiency.
Implementation Method 1
a 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 connected to the laminate for mounting the solar module on a surface of the structure. The mount includes features to facilitate mounting the solar module on a surface or positioning the solar module in a solar array with other solar modules.