Stackable Rooftop PV Module Frame for Lightweight Mounting
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Solution Overview
Problem
Existing rooftop solar panel mounting systems are complex, heavy, require multiple roof penetrations, extensive grounding, and skilled labor for installation, leading to high costs and logistical challenges.
Innovation Solution
A lightweight, pre-assembled solar panel mounting system integrated with a supporting frame made from non-conductive materials like wood plastic composite, allowing for easy transportation and installation, with a modular design that enables stacking and secure attachment to rooftops using a combination of connectors and ballast for stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional metal rack mounting systems are used, then structural strength and stability are improved, but weight and device complexity increase significantly
Solution Approach 1:
The patent applies composite materials by using wood plastic composite (WPC) instead of traditional metal materials for the mounting system components. The WPC material provides sufficient structural strength while significantly reducing weight, eliminating the need for extensive grounding systems and making the modules easier to transport and install.
Solution Approach 2:
The patent merges the mounting frame and solar panel into a single integrated module. The aluminum frame is directly attached to the rear of the solar panel, combining structural support and panel mounting functions into one unified component, reducing overall system complexity and weight.
2Reliability
If custom-built rack mounting solutions are acquired, then installation precision and reliability are improved, but manufacturing cost and device complexity increase
Solution Approach 1:
The mounting frame is pre-assembled and pre-attached to the solar panel at the factory before shipping to the installation site. This preliminary assembly ensures proper alignment and structural integrity, reducing on-site installation complexity and ensuring reliable installation without requiring custom-built solutions.
Solution Approach 2:
The integrated module design creates a universal mounting solution that can be installed on various roof types (asphalt shingle, metal, tile, flat roofs) using different attachment methods. The same module design serves multiple installation scenarios, reducing the need for custom-built solutions for different applications.
3Ease of operation
If modular integrated design is used, then ease of installation and transport are improved, but structural strength and stability may worsen
Solution Approach 1:
The patent uses curved or angled support structures within the mounting frame to provide structural strength. The curved design elements distribute loads more effectively and provide inherent structural rigidity while maintaining the lightweight modular design, ensuring stability in windy or seismic conditions.
Solution Approach 2:
The use of wood plastic composite material provides both the necessary structural strength and the lightweight properties needed for easy installation. The composite material's inherent strength-to-weight ratio allows the modular design to maintain structural integrity without requiring heavy components.
Data Source
AI summary
A photovoltaic module may include a first frame portion defining a first plane, a second frame portion defining a second plane angled relative to the first plane, and a photovoltaic panel mounted to the second frame portion. The second frame portion may be supported only at opposing ends. The photovoltaic module may be stackable with similar modules.