Solar panel with integral cable management
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Solution Overview
Problem
The existing solar panel installation process is inefficient, requiring multiple installers, leading to wasted time and safety issues due to loose hardware, exposed cables, and rodent damage, which can cause electrical hazards and system failures.
Innovation Solution
A solar panel mounting system with a modular peripheral frame and pre-installed captive T-bolt assemblies that allow for rapid installation with one installer, internal cable routing, and a snap-in rodent-proof conduit cover to secure cables, eliminating the need for manual handling of hardware and reducing exposure to rodents.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If traditional loose mounting hardware is used to secure solar panels to rails, then the panels can be mounted to the support structure, but the hardware becomes loose and dislodged during installation requiring multiple installers and creating safety hazards
Solution Approach 1:
The mounting hardware (captive clips and bolts) is pre-assembled and pre-positioned on the solar panel frame before installation. This preliminary action ensures that all hardware components are securely attached to the panel, eliminating the risk of loose hardware during the installation process and allowing single-installer deployment.
Solution Approach 2:
The mounting hardware is merged with the solar panel frame by permanently attaching clips and bolts to the frame structure. This integration ensures that hardware cannot become loose or dislodge separately from the panel, maintaining both safety and reliability throughout installation and operation.
2Productivity
If traditional field installation of wire clips is used to secure cables to panel frames, then cables can be attached, but it adds significant time to installation requiring 6-8 clips per panel
Solution Approach 1:
Wire clips and cable routing features are pre-installed on the solar panel frame during manufacturing. This preliminary action eliminates the need for installers to manually attach multiple wire clips in the field, reducing cable securing time from minutes per panel to a simple snap-in operation and significantly improving installation productivity.
3Ease of manufacture
If cables are externally routed and mounted on solar panels, then cable connections can be made, but cables remain exposed and vulnerable to rodent damage creating electrical hazards
Solution Approach 1:
Cables are routed internally through channels and conduits integrated into the solar panel frame structure. This nesting approach protects cables from external rodent access while maintaining simple cable routing, as cables are guided through pre-formed pathways within the frame rather than requiring complex external routing.
Solution Approach 2:
The frame structure, which could be seen as adding complexity to cable routing, is converted into a protective element by incorporating internal cable channels. This transforms the frame from a simple mounting structure into a protective conduit system that shields cables from rodent damage while maintaining routing simplicity.
4Adaptability or versatility
If conventional mounting systems are used, then solar panels can be installed on support rails, but the process is cumbersome and requires additional installers and materials
Solution Approach 1:
Multiple mounting functions (panel attachment, cable management, and alignment) are merged into a single integrated frame structure with pre-assembled hardware. This consolidation maintains adaptability for standard rail mounting while eliminating the need for separate hardware components, thereby reducing overall system complexity and enabling single-installer deployment.
Data Source
AI summary
A solar panel mounting system for forming a solar array includes longitudinal support rails mounted to a support structure such as a roof. A first solar panel disposed on the rails has a peripheral frame including a locking frame member with deformable clamping portion configured for slideably receiving a peripheral frame portion of an adjacent second solar panel. A pair of captive T-bolt sets passing through the clamping portion include T-bolts having locking heads and nuts frictionally engaged with the T-bolts to rotate the T-bolts. The heads are each inserted and rotationally locked into fastening channels of respective support rails. The second solar panel is inserted into the first panel clamping portion and the nuts are fully tightened producing a clamping action which locks the first and second panels together. Power/control cables may be routed inside covered cable compartments on rears of the panels for protection against rodent damage.