Wire Management Structure for Rail-Less Solar Panel Assembly
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Solution Overview
Problem
The installation of solar panel arrays on residential roofs is arduous and time-consuming due to the complexity of existing assembly components, particularly in rail-less configurations, which require specialized tools and are difficult to adjust and level without additional tools.
Innovation Solution
A system utilizing a barrel nut with a drive head integrated into the clamp for adjustment, linear bonding pins and clamps for electrical bonding, and a wire management system with conduits and pivoting tabs to simplify the installation process, eliminating the need for rotating leveling bolts and additional securing mechanisms.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a rotating leveling bolt is used to adjust clamp assemblies, then the clamp can be adjusted and leveled, but additional specialized tools are required and the adjustment process becomes more complex
Solution Approach 1:
The patent combines the leveling adjustment function directly into the clamp assembly by integrating a barrel nut and barrel bolt mechanism. The barrel nut is threaded onto the barrel bolt, and rotating the barrel bolt adjusts the clamp's position. This integration eliminates the need for separate rotating leveling bolts and reduces the number of components, making the adjustment process simpler and requiring only basic hand tools.
Solution Approach 2:
The barrel bolt serves multiple functions: it acts as both the adjustment mechanism for leveling the clamp and as a structural component of the clamp assembly itself. This multi-functionality reduces the need for specialized tools and simplifies the overall adjustment process, as the same component performs both structural support and adjustment functions.
2Reliability
If additional specialized tools are used for installation, then solar panel modules can be secured to support elements, but the installation process becomes more difficult and time-consuming
Solution Approach 1:
The patent combines the electrical bonding function with the mechanical clamping function by integrating linear bonding pins into the clamp assembly. These pins pass through aligned holes in the clamp and the solar panel module, providing both mechanical securing and electrical grounding in a single operation. This integration eliminates the need for separate bonding tools and steps, reducing installation time while maintaining secure attachment and proper electrical grounding.
Solution Approach 2:
The clamp assembly is segmented into distinct functional components: the barrel nut for adjustment, the barrel bolt for leveling, the clamping arms for mechanical securing, and the linear bonding pins for electrical grounding. This segmentation allows each component to perform its specific function efficiently, and all components can be installed using basic hand tools, reducing the need for specialized equipment and speeding up the installation process.
3Ease of operation
If wire bundles are not managed, then installation is simpler, but wire safety and convenience are compromised
Solution Approach 1:
The patent integrates wire bundle management into the clamp assembly by incorporating a conduit that receives and secures wire bundles. The conduit is positioned within the clamp structure, allowing wires to be routed through or alongside the clamp components. This integration provides organized wire management and safe wire routing without requiring separate wire management devices, maintaining ease of operation while ensuring wire safety and convenience.
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 providing a leveling system that utilizes a barrel bolt and barrel nut to vertically adjust the assembly. Improved electrical bonding by utilizing bonding pins installed in mounting plates of a support clamp are also provided. Additionally, an improved array skirt design that is installed on the outer row of the array, as well as improved designs in the support clamp and splice mechanisms are also provided. Finally, an improved wire management system is included as well as a method of installation of the array assembly.