Expandable Torque Tube Splice for Solar Wind Load Distribution

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Solution Overview

Problem

Solar power systems face structural deflection, bending, or failure under high wind loads due to inadequate load distribution along support structures like torque tubes, leading to inefficiencies and potential damage.

Innovation Solution

An expandable splice with beveled corner panels that transitions between a narrow configuration for easy insertion into support channels and an expanded configuration to distribute loads along the support structure, preventing warping or bowing by securing side panels against the inner surface of the torque tube.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If additional support is applied to the array of solar modules or the specific point of attachment, then the local strength is improved, but the load distribution along the torque tube remains insufficient, resulting in continued distortion or bending

Engineering Contradiction:

Improvelocal strength at attachment pointVSAvoidload distribution along torque tube

Core Design Contradiction:

StrengthVSReliability

Solution Approach 1:

The splice is divided into multiple panels (first side panel, second side panel, top panel, bottom panel) that can independently expand and distribute forces along different segments of the torque tube, preventing concentrated loads at single attachment points

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The splice transitions from a narrow configuration to an expanded configuration by moving panels outward in the radial dimension, increasing the distribution area along the torque tube length and preventing bending through three-dimensional load dispersal

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

2Ease of operation

If the splice is designed in a narrow configuration for easy insertion into the support channel, then the ease of installation is improved, but the structural reinforcement capability is reduced

Engineering Contradiction:

Improveease of insertion into support channelVSAvoidstructural reinforcement capability

Core Design Contradiction:

Ease of operationVSStrength

Solution Approach 1:

The splice is designed as a dynamic structure that can transition between narrow and expanded configurations, allowing it to be easily inserted in the narrow state and then expanded to provide maximum reinforcement capability

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The narrow configuration allows the splice panels to be nested or collapsed into a compact form that fits within the support channel, while the expanded configuration allows panels to protrude for reinforcement

Inventive Principle:

Principle #7Nested doll (Nesting)

3Productivity

If the array of solar modules is exposed to high winds, then the energy generation potential is improved, but the wind forces concentrate at connections and fasteners, potentially resulting in deflection, bending, or failure

Engineering Contradiction:

Improveenergy generation potentialVSAvoidwind load concentration at connections

Core Design Contradiction:

ProductivityVSObject-affected harmful factors

Solution Approach 1:

The splice captures the concentrated wind forces that would otherwise harm the connections and fasteners, and redistributes these forces along the entire length of the torque tube through its expanded panel structure, converting a harmful concentration into a beneficial distribution

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

Solution Approach 2:

The splice is pre-installed in the support channel before exposure to high winds, creating a protective reinforcement structure that is already in place to distribute loads before wind forces concentrate at vulnerable connection points

Inventive Principle:

Principle #10Preliminary action

Data Source

PatentUS11588434B2Expandable splice for a solar power system

Publication Date: 2023.02.21 NEXTPOWER LLC

AI summary

The present disclosure describes an expandable splice configured for reinforcing a tube of a solar owner system, the splice including a top panel, a bottom panel, a first side panel, a second side panel, and at least one beveled corner panel, wherein the first and second side panels are connected to the top and bottom panels either directly or by the at least one beveled corner panel to form a channel therebetween.