Spring Lock Grounding Assembly for Rail-Less Solar Modules
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Solution Overview
Problem
The installation of solar panel arrays on residential roofs is arduous and time-consuming, especially in rail-less guide systems, due to the difficulty in securing and grounding solar panel modules without additional or complicated tools.
Innovation Solution
A rail-less solar panel array configuration using semi-rigid spring locks with grounding features, where each solar panel module is secured by inserting it at an acute angle and rotated downward to lock into place, utilizing the resiliency of the spring lock to resist force and create an electrical grounding path through a raised portion on the tab.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If discrete mounting components are used in a rail-less configuration, then the installation process becomes more complex and time-consuming, but the structural support and electrical grounding requirements must still be met
Solution Approach 1:
The spring lock tab integrates multiple functions into a single component: it provides mechanical locking by engaging with the module edge, electrical grounding through the conductive body contacting the module frame, and structural support by securing the module to the mounting component. This merging of functions reduces the number of separate components needed and simplifies the installation process.
Solution Approach 2:
The spring lock tab serves multiple purposes simultaneously: it acts as a mechanical fastener, an electrical ground connection, and a structural support element. This multi-functionality addresses both the mechanical securing and electrical grounding requirements in a single integrated component, reducing installation complexity and time.
2Reliability
If additional tools are required to secure solar panels, then the securing mechanism may be more reliable, but the installation process becomes more difficult and time-consuming
Solution Approach 1:
The spring lock tab is designed to be installed by hand without requiring additional tools. The installer simply inserts the tab through the mounting component and bends it into the locked position, allowing the tab to self-secure the module through its resilient properties. This self-service installation maintains reliability while significantly improving ease of operation.
Solution Approach 2:
The spring lock tab utilizes elastic deformation and resilient recovery to provide both ease of installation and secure locking. The tab can be easily bent into position by hand during installation, then automatically exerts continuous locking force as it returns to its original shape, ensuring reliable securing without requiring tools.
3Ease of operation
If the spring lock tab is made more resilient to facilitate easy installation, then the ease of operation improves, but the locking force and securing strength may be reduced
Solution Approach 1:
The spring lock tab's material properties and geometric parameters are optimized to achieve the right balance: the tab is made from material with appropriate elastic modulus and is designed with specific dimensions (width, thickness, length) that provide sufficient resilience for hand installation while maintaining adequate locking force. The parameters are tuned so the tab can be bent during installation but exerts sufficient force when locked.
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
Enables quick and efficient installation of solar panel arrays with minimal effort, allowing installers to secure and ground modules easily, overcoming the limitations of existing solutions by simplifying the process and eliminating the need for additional tools.
Implementation Method 1
utilizing the resiliency in the spring lock tab to resist the force exerted on the side of the module and push outward against the side to allow the module to be inserted and secured within the lip
Implementation Method 2
a raised portion on the outer edge of the tab penetrates an oxidation layer on the module, which allows the module to be electrically grounded to the mount
Data Source
AI summary
In various representative aspects, an assembly for securing array skirts and solar panel modules in an array on a roof by utilizing semi-rigid and resilient spring tabs as locking mechanisms that both secure the solar panel modules to mounting plates and splices as well as provide a grounding path between the solar panel modules and the entire array. A method of installation of the assembly is also provided.