Solar Panel with Pivoting Side Supports for Reduced Installation Cost
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Solution Overview
Problem
The challenge in the solar panel industry is to reduce installation time and costs while maintaining structural integrity and efficiency, particularly for flat roof installations, where existing solar panels require significant labor and materials, leading to increased expenses.
Innovation Solution
The development of photovoltaic modules with repositionable side supports that can be folded for compact shipping and easy mounting, allowing for efficient stacking and reduced labor costs, while maintaining structural integrity through electrical grounding and adjustable height attachments for uneven surfaces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional fixed side supports are used on solar panels, then structural integrity is maintained, but shipping volume increases and installation time increases
Solution Approach 1:
The side supports are designed to pivot between a horizontal shipping position and a vertical installation position. This dynamic reconfiguration allows the same structure to serve dual purposes: compact stacking during transport and proper structural support during installation, eliminating the need for separate configurations.
Solution Approach 2:
The support structure is divided into modular side supports that can be independently positioned and configured. Each side support acts as an independent unit that can pivot and lock into place, allowing for simplified assembly and reduced installation complexity while maintaining overall structural integrity.
2Volume of stationary object
If solar panels are shipped with side supports in extended position, then structural integrity is maintained, but shipping volume and transportation costs increase
Solution Approach 1:
The side supports pivot to a horizontal position during shipping, reducing the overall panel assembly volume and allowing for more efficient stacking. The same supports then pivot to a vertical position during installation to provide the necessary structural strength, dynamically adapting to different operational requirements.
Solution Approach 2:
The side supports are designed to nest against the panel frame when in the horizontal shipping position, maximizing compactness. During installation, they pivot outward to their functional position, providing structural support without requiring additional space during transport.
3Loss of time
If traditional installation methods are used, then structural integrity is ensured, but labor costs and installation time increase
Solution Approach 1:
The side supports are pre-configured in a compact horizontal position during manufacturing and shipping. This preliminary configuration eliminates the need for complex assembly steps during installation - installers simply pivot the supports to their vertical position and secure them, dramatically reducing installation time and labor requirements.
Solution Approach 2:
The pivoting side supports are designed to be self-aligning and self-securing through their mechanical pivot mechanism. The supports automatically assume their correct vertical position when activated, reducing the need for precise manual alignment and complex fastening procedures, thereby simplifying the installation process.
4Strength
If thick frames are used to strengthen solar panels, then structural integrity is improved, but material costs and weight increase
Solution Approach 1:
Instead of using permanently thick frames, the patent employs thin frames combined with dynamic pivoting side supports. The supports provide structural strength only when needed in the vertical installation position, allowing the frame itself to be lighter while maintaining overall panel strength during both shipping and installation phases.
Data Source
AI summary
A folded down support (12) allows for stronger solar panels (10) and the support replaces most of the solar racking required for solar installation which further reduces the cost of the photovoltaic solar system. The solar panels (10) can be arranged so that solar panels form a solar collector solar panel array. The solar panel (10) can be set on a surface by itself or with ballast (43). It can also be attached to the surface by fastening the solar panel to the side supports. If the solar panel frame and supports are electrically conductive, the design allows for self electrical grounding between these conductive parts when the side supports are pivoted to the down position. The folded up support allows for high density storage and shipping.