Clamp apparatuses and components thereof for mounting solar panel modules
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Solution Overview
Problem
Existing solar panel module clamps lack ease of installation, durability, strength, and effective electrical bonding, often being overly complex or insufficiently secure.
Innovation Solution
A universal clamp assembly comprising a clamp, nut, and connection member that accommodates modules of varying thicknesses, featuring adjustable height and secure electrical bonding through a rhomboidal head that traps in a rail segment slot, with protrusions for puncturing layers to ensure electrical connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If existing clamp designs are used, then installation can be completed, but the installation process is time-consuming and lacks ease of installation
Solution Approach 1:
The clamp is divided into multiple independent components: a clamp body with clamp arms, a separate fastening mechanism with bolt and nut, and modular electrical bonding elements. This segmentation allows for simplified assembly where each component has a specific function, enabling quick installation without complex integration steps.
Solution Approach 2:
The clamp arms are pre-configured with electrical bonding surfaces and the fastening mechanism is pre-assembled with the clamp body. The electrical bonding protrusions are pre-positioned to align with rail slots during installation. This preliminary preparation eliminates the need for on-site adjustments or complex alignment procedures, significantly reducing installation time.
2Adaptability or versatility
If clamp designs include multiple features for versatility, then adaptability improves, but device complexity increases
Solution Approach 1:
The clamp body is designed as a universal component that can accommodate solar panels of varying thicknesses through adjustable clamp arms. The same clamp body serves multiple functions: mechanical clamping, electrical bonding, and positioning. The fastening mechanism with bolt and nut provides universal adaptability for different panel configurations without requiring multiple specialized clamp designs.
Solution Approach 2:
The clamp arms are designed to be adjustable in position and angle, allowing the clamp to adapt dynamically to different panel thicknesses and orientations. The fastening mechanism allows for incremental adjustment during installation to achieve proper clamping force and electrical contact. This dynamic adjustability provides versatility without requiring multiple fixed-design clamps for different scenarios.
3Device complexity
If clamp designs are simplified, then device complexity reduces, but electrical bonding effectiveness deteriorates
Solution Approach 1:
The electrical bonding function is merged with the mechanical clamping function in the same clamp structure. The clamp arms incorporate electrical bonding surfaces that make direct contact with the solar panel frame during clamping. The fastening mechanism simultaneously provides both mechanical securement and electrical connection through integrated bolt and nut assemblies, eliminating the need for separate bonding components.
Solution Approach 2:
The clamp arms serve as intermediary elements between the fastening mechanism and the solar panel frame. They transmit both mechanical clamping force and electrical current from the rail to the panel. The electrical bonding protrusions on the clamp arms act as mediators that ensure reliable electrical contact by puncturing through protective layers to reach conductive surfaces, maintaining bonding effectiveness without adding complex separate bonding systems.
4Strength
If existing clamps are used, then basic securing is achieved, but durability and strength are insufficient
Solution Approach 1:
The clamp assembly utilizes composite construction combining different materials optimized for specific functions: the clamp body and arms use high-strength, corrosion-resistant materials for structural integrity; the electrical bonding surfaces use conductive materials with appropriate surface properties for reliable electrical contact; the fastening components use hardened materials for durability. This composite approach ensures both strength and durability without over-engineering the entire structure.
Solution Approach 2:
The clamp design incorporates protective features that preemptively address potential failure modes. The clamp arms are designed with sufficient material thickness and structural reinforcement to withstand anticipated mechanical loads and environmental degradation. The electrical bonding protrusions are designed to puncture through protective layers to ensure reliable contact even if surface conditions deteriorate. The fastening mechanism includes corrosion-resistant coatings and designs that prevent degradation over time, ensuring long-term durability before failures can occur.
Data Source
AI summary
A clamp assembly includes a clamp with a lateral edge support portion that extends in a first direction to support against a lateral edge of the module. A flange extends in a second direction transverse to the first direction to clamp against an upper surface of the solar panel module in coordination with the lateral edge support portion. A nut is configured to align with the clamp. The nut receives a fastener. The nut has an outer surface to engage the second surface of the lateral edge support portion to prevent rotation of the nut. A connection member extends from the nut in a position that is fixed. A head of the connection member is shaped such that, in a first orientation, the head is accommodated passage through a slot in the intermediary member, and in a second orientation, the head is prevented from passage through the slot.