Support structures and mounting systems for solar panels
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Solution Overview
Problem
The high cost and complexity of manufacturing and installing solar panels due to their large and heavy nature, which requires robust frames for support and mounting, necessitate a need for cost-effective and simplified support structures and mounting systems.
Innovation Solution
A support structure with movable lock tabs and a frame design that includes a first and second shelf with upturns, allowing for easy engagement of frame sections, and a dividing structure that enhances strength and durability while reducing material and assembly costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional frames are used to support solar panels, then strength and durability are improved, but manufacturing cost and complexity increase
Solution Approach 1:
The frame is divided into multiple frame sections (first frame section, second frame section, etc.), each supported by separate support structures with shelves and lock tabs. This segmentation allows each component to be manufactured independently and assembled together, reducing overall complexity while maintaining structural strength through modular construction.
Solution Approach 2:
The support structure incorporates movable lock tabs that can move between engaged and disengaged positions, allowing the frame sections to be easily assembled and disassembled. This dynamic element provides secure attachment when engaged while simplifying the assembly process, reducing both manufacturing and installation complexity.
2Reliability
If traditional mounting systems are used, then secure attachment is achieved, but assembly time and installation cost increase
Solution Approach 1:
The support structures and frame sections are designed with pre-configured shelves, upturns, and lock tabs that are positioned and shaped in advance during manufacturing. This preliminary action ensures that during installation, the components can be quickly assembled by simply engaging the pre-positioned elements, reducing assembly time while maintaining secure attachment.
Solution Approach 2:
The movable lock tabs are designed to automatically engage with the frame sections when the support structure is installed, providing self-securing functionality. This self-service mechanism eliminates the need for complex fastening procedures or additional tools during installation, reducing assembly time while ensuring reliable attachment.
3Duration of action of stationary object
If more materials are used to strengthen frames, then durability is improved, but manufacturing cost increases
Solution Approach 1:
By dividing the frame into multiple sections supported by separate support structures, each component can be manufactured using less material than a single monolithic frame would require. The modular approach distributes the structural load across multiple smaller elements, maintaining overall durability while reducing total material consumption and manufacturing cost.
Solution Approach 2:
The movable lock tabs provide dynamic securing capability that enhances frame durability without requiring additional materials. The ability of these tabs to move and engage securely with frame sections creates strong mechanical connections through design rather than material quantity, reducing manufacturing costs while maintaining or improving durability.
Data Source
AI summary
A solar panel support structure includes a first shelf for supporting a first frame section of a first solar panel module, the first shelf defining a first plane, and a second shelf for supporting a second frame section of a second solar panel module, the second shelf defining a second plane. A dividing structure is provided between the first and second shelves and extends above the first and second planes. A first shelf upturn may be provided at an end of the first shelf away from the dividing structure and extending above the first plane. A second shelf upturn may be provided at an end of the second shelf away from the dividing structure and extending above the second plane. The support structure includes one or more first movable lock tabs for engaging first and second bottom flange portions of the frame sections.