Adjustable Rooftop PV Mounting Without Flashings
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Solution Overview
Problem
Existing rail-free photovoltaic mounting systems for composite shingle roofs are costly and time-consuming due to the reliance on flashings, which require additional materials, tools, and labor, and create installation bottlenecks as all flashings must be correctly positioned and installed before solar panels can be placed.
Innovation Solution
A two-piece mounting system with a planar base portion and a movable portion that allows lateral and rotational adjustment, secured by a pivot point and fastener, eliminating the need for flashings by enabling in-step installation with photovoltaic modules, while using a sealing adhesive to prevent water ingress.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If flashings are used in rail-free mounting systems, then water leakage protection is improved, but installation time and hardware cost increase
Solution Approach 1:
The patent removes flashings from the mounting system entirely, extracting this component from the assembly. The base portion with integrated seal creates a simplified system that eliminates the need for separate flashing components while maintaining water protection functionality.
Solution Approach 2:
The patent combines the sealing function previously performed by flashings into the base portion itself. The base portion integrates both structural support and water sealing capabilities, merging multiple functions into a single component that reduces installation steps.
2Reliability
If flashings are used in rail-free mounting systems, then water leakage protection is improved, but hardware cost increases
Solution Approach 1:
The patent removes flashings from the mounting system entirely, extracting this component from the assembly. The base portion with integrated seal creates a simplified system that eliminates the need for separate flashing components while maintaining water protection functionality.
Solution Approach 2:
The patent combines the sealing function previously performed by flashings into the base portion itself. The base portion integrates both structural support and water sealing capabilities, merging multiple functions into a single component that reduces installation steps.
3Reliability
If flashings are used in rail-free mounting systems, then water leakage protection is improved, but installation process complexity increases
Solution Approach 1:
The patent removes flashings from the mounting system entirely, extracting this component from the assembly. The base portion with integrated seal creates a simplified system that eliminates the need for separate flashing components while maintaining water protection functionality.
Solution Approach 2:
The patent combines the sealing function previously performed by flashings into the base portion itself. The base portion integrates both structural support and water sealing capabilities, merging multiple functions into a single component that reduces installation steps.
4Reliability
If all flashings are installed before solar panels, then water leakage protection is ensured, but installation bottleneck occurs
Solution Approach 1:
The base portion with integrated seal is pre-configured with water protection capabilities, eliminating the need for separate flashing installation. This preliminary integration of sealing functionality allows installers to proceed directly to panel installation without the bottleneck of installing all flashings first.
Solution Approach 2:
The mounting system is segmented into modular base portions that can be installed individually as needed, rather than requiring complete flashing installation upfront. This segmentation allows for progressive installation that improves workflow efficiency.
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
This solution reduces installation times, hardware costs, and part counts, allowing for faster and more efficient installation of photovoltaic modules by enabling 'install-as-you-go' techniques without compromising the benefits of rail-free systems.
Implementation Method 1
a layer of butyl or other sealing adhesive that provides a seal between the underside of the base portion and a roof surface around the hole containing the lag bolt that attaches the base portion to the roof, thereby preventing the ingress of water via the roof penetration
Data Source
AI summary
A two-piece rooftop photovoltaic mounting system. A fixed base portion is attached directly to a roof surface via a lag bolt or other mechanical fastener. A movable portion is attached to and pivots about the base portion providing freedom of movement radially and axially with respect to the base portion. A photovoltaic module coupler is attached to the movable portion to support at least two photovoltaic modules at a location dictated by positioning of the movable portion. A locking nut locks the movable portion to the base portion at the desired location. A sheet of sealant material under the base portion helps prevent ingress of water into the roof surface via the lag bolt.