Spring Clamp Adapter for Bolt-Less PV Module Mounting
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Solution Overview
Problem
Conventional bolted connections for solar panels are inefficient due to lack of standardization in panel dimensions and mounting hole positions, leading to increased manufacturing and supply chain costs, complex installation processes, and high maintenance requirements due to torqueing issues and potential for over- or under-tightening.
Innovation Solution
A clamp adapter system with a rail slot, lower flange, and lateral flange that allows for elastic deformation to accommodate various panel sizes and orientations, providing a bolt-less attachment mechanism that includes teeth for improved grip and electrical contact, reducing the need for torque specification and simplifying installation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional bolted connections are used to attach solar panels, then mechanical attachment and electrical bonding can be achieved, but manufacturing and supply chain costs increase due to lack of standardization in panel dimensions and mounting hole positions
Solution Approach 1:
The clamp adapter is designed with a universal structure that can accommodate multiple panel types and mounting configurations through a single standardized interface. The adapter body with its specific geometry (45-degree angled surfaces, flange configurations) allows it to work with various panel dimensions and hole positions, eliminating the need for customized mounting solutions for each panel type.
Solution Approach 2:
The clamp adapter utilizes elastic deformation of its body to adapt to different mounting scenarios. The material and structural design allow the adapter to flex and conform to varying panel orientations and positions, providing adjustment capability without requiring multiple specialized components.
2Reliability
If conventional bolted connections are used to attach solar panels, then secure mechanical attachment can be achieved, but installation process complexity increases
Solution Approach 1:
The clamp adapter extracts and eliminates the need for separate bolts, nuts, and washers by integrating the fastening function into a single spring-loaded clamp component. This single-component design replaces the multi-part bolted connection system, simplifying the installation process while maintaining secure attachment through the spring mechanism's clamping force.
Solution Approach 2:
The spring-loaded clamp mechanism is designed to self-adjust and self-secure during installation. The elastic material and spring force automatically provide the necessary clamping pressure without requiring external tools or complex tightening procedures, making the installation process more straightforward while ensuring reliable attachment.
3Reliability
If conventional bolted connections are used to attach solar panels, then mechanical attachment can be achieved, but maintenance requirements increase due to torqueing issues and potential for over- or under-tightening
Solution Approach 1:
The spring-loaded clamp mechanism maintains constant clamping force through its elastic properties, automatically compensating for any settling or thermal expansion without requiring manual adjustment. The spring force self-regulates to provide optimal attachment pressure, eliminating the need for periodic torque checks and adjustments that are necessary with conventional bolted connections.
Solution Approach 2:
The clamp adapter transitions from a static bolted connection to a dynamic spring-loaded system that can adapt to changing conditions. The elastic material allows the clamp to flex and maintain consistent contact pressure despite variations in panel position, temperature, or load, providing more reliable attachment with less maintenance.
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
The clamp adapter system enables rapid, ergonomic, and cost-effective solar panel installation with reduced maintenance needs by eliminating the complexity of bolted connections and ensuring secure, standardized attachment without requiring precise torque values.
Implementation Method 1
a lateral flange configured to be biased against a surface of the portion of the structure to retain the structure in the rail slot
Implementation Method 2
a lateral flange configured to be biased against a surface of the portion of the structure to retain the structure in the rail slot
Data Source
AI summary
Mounting systems for solar panel assemblies and related methods are generally described. In some embodiments, a clamp adapter may be used to mount a conventional panel support structure of a solar panel assembly to a conventional bracket of a base assembly without the use of bolts in at least some embodiments. The clamp adapter may include a rail slot for receiving the structure, a lower flange for receiving a lower surface of a mounting lip of the bracket, and a lateral flange for receiving an upper surface of the mounting lip. The lower flange may be angled to accommodate a variety of mounting lip angles. In some embodiments, the mounting system may also include a connector configured to mechanically connect the bracket and structure.