Adjustable Roof Mount Bracket for Variable Solar Panel Heights
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Solution Overview
Problem
Existing roof mount systems lack an efficient and adjustable mechanism for securely mounting solar panels on roofs, particularly in terms of accommodating varying panel sizes and heights, while also providing a watertight seal and electrical connectivity.
Innovation Solution
A roof mount system featuring a base with a slot for horizontal adjustment, a clamp with adjustable height and recesses for solar panels, and a fastener that adjusts the height by deflecting a resilient wall, allowing for secure mounting and electrical connectivity, along with a skirt to prevent water ingress and pressure differentials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a fixed-height mounting system is used, then the structure is simple, but it cannot accommodate solar panels of varying sizes and heights
Solution Approach 1:
The mounting system employs adjustable height mechanisms that allow the structure to dynamically adapt to different solar panel heights. The system transitions from a fixed configuration to a variable one, enabling accommodation of various panel sizes while maintaining structural integrity through controlled adjustability rather than complete redesign.
Solution Approach 2:
The system changes the height parameter of the mounting structure to match different solar panel specifications. By allowing the mounting height to be variable rather than fixed, the system can accommodate panels of varying sizes without requiring complete structural replacement, thus balancing adaptability with reasonable complexity.
2Adaptability or versatility
If an adjustable height mechanism is added, then adaptability to varying panel sizes is improved, but the device complexity increases
Solution Approach 1:
The patent combines the height adjustment function with the clamping mechanism into a single integrated assembly. The fastener simultaneously performs both height positioning and panel securing functions, reducing the number of separate components needed and simplifying the overall device complexity while maintaining the required adaptability.
Solution Approach 2:
The clamp and fastener assembly is designed to perform multiple functions: height adjustment, panel clamping, and structural support. This multi-functional design reduces the need for separate specialized components, thereby limiting the increase in device complexity while achieving the desired height adaptability.
3Manufacturing precision
If a resilient wall deflection mechanism is used for height adjustment, then precise height control is achieved, but the manufacturing precision requirements increase
Solution Approach 1:
The system uses elastic deformation of the resilient wall as a mechanism for height adjustment. By changing the physical state of the material from rigid to elastically deformable, the system achieves precise height control through controlled deflection rather than requiring extremely tight manufacturing tolerances on rigid components.
Solution Approach 2:
The resilient wall functions as a flexible element that can be deflected to achieve height adjustment. This flexible component approach allows for tolerance compensation and easier manufacturing compared to rigid precision mechanisms, as the elasticity of the material provides self-adjusting characteristics that reduce the need for extremely precise manufacturing.
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
The system provides a secure, adjustable, and watertight method for mounting solar panels of varying sizes, ensuring effective water management and electrical connectivity, enhancing the stability and efficiency of solar panel installations on roofs.
Implementation Method 1
a resilient wall positioned between the first and second bottom flanges... upon tightening of the second fastener, the first height increases and the second height decreases
Data Source
AI summary
A roof mount for mounting at least one solar panel to a roof surface including a base. The roof mount includes a clamp connected to the base and a first recess sized to support a first solar panel. The first recess has a first height extending between a first top flange and a first bottom flange. The clamp also includes a second recess sized to support one of a second solar panel and a skirt flange. The second recess has a second height extending between a second top flange and a second bottom flange. The roof mount further includes a fastener connected to the clamp. The second fastener is operable to adjust the first and second heights, such that upon tightening of the second fastener, the first height increases and the second height decreases, and upon loosening of the second fastener, the first height decreases and the second height increases.