Photovoltaic module stackable corner protector
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The manual removal of corner protectors from photovoltaic modules is time-consuming and inefficient, especially when dealing with large quantities, as they typically need to be removed one at a time, which increases the risk of damage during the process.
Innovation Solution
A stackable corner protector design featuring cylindrical support structures with protrusions and attachment features that allow for simultaneous installation and removal, enabling the protector to be rotated away from the module while remaining supported, and featuring different geometries to prevent incorrect installation and secure engagement with the module's lip.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional corner protectors are used, then the modules are protected from damage, but the removal process is time-consuming and must be done one at a time
Solution Approach 1:
Multiple corner protectors are merged into a single stackable unit through vertical stacking and interlocking mechanisms. The protectors stack vertically with each protector forming a column, and multiple columns are connected through engagement features that allow simultaneous removal of all protectors in the stack, transforming individual removal operations into a single collective removal action.
Solution Approach 2:
The corner protector is divided into modular components including a body portion, support structures with cylindrical shapes, and interlocking engagement features. These segmented components allow the protectors to stack vertically while maintaining individual integrity, enabling the stack to function as a unified removable unit while preserving the protective function of each individual corner protector.
2Reliability
If corner protectors are securely attached to modules, then protection is ensured, but removal becomes difficult and time-consuming
Solution Approach 1:
The attachment mechanism uses dynamic engagement features including cam-actuated latches and spring-loaded locking components. These features allow the corner protectors to be securely locked during transportation through automatic engagement, but can be quickly released during removal through a simple actuating motion that disengages all protectors in the stack simultaneously, providing both secure attachment and easy removal.
Solution Approach 2:
The corner protectors are pre-configured with interlocking engagement features and alignment guides that automatically engage when stacked. The preliminary arrangement of protrusions and recesses ensures that when the stack is formed, all protectors are pre-positioned and pre-locked together, so that a single removal action automatically disengages all protectors in the correct sequence without requiring manual manipulation of each individual protector.
3Manufacturing precision
If multiple corner protectors are handled individually, then proper installation is ensured, but the process is inefficient and increases damage risk
Solution Approach 1:
Multiple corner protectors are combined into a single stackable assembly where each protector maintains its precise geometric configuration. The stackable design allows all protectors to be installed and removed as a single unit while the rigid structural framework ensures that each individual protector remains properly positioned and oriented throughout the process, eliminating the time loss of individual handling while preserving installation precision.
Solution Approach 2:
The corner protectors are pre-assembled into stacked configurations with alignment features and engagement mechanisms already in place. This preliminary stacking ensures that when the protectors are removed from packaging, they are already in their final installed configuration, eliminating the need for sequential individual installation and ensuring that each protector is correctly positioned from the start without requiring time-consuming individual adjustment.
Data Source
AI summary
The disclosure describes various stackable corner protector configurations. The corner protectors can have curved lateral surfaces that allow the corner protectors to be decoupled from a photovoltaic module to which they are coupled to by rotating one end of the corner protectors away from the object. This removal process works even more efficiently with multiple stacked corner protectors as the stacked corner protectors can be concurrently removed from the object by rotating the stacked corner protectors away from the object together. The corner protector can also include one or more attachment features for securing the corner protector to the object. For example, when the corner protector is installed on a photovoltaic module, the attachment feature can engage a lip defined by a recess or channel of the photovoltaic module.