Supported PV module assembly
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Solution Overview
Problem
Existing PV installations face challenges in minimizing wind uplift forces, which require heavy ballast and penetrating fasteners, increasing installation costs and potentially damaging roof membranes, while also being cumbersome to transport and install.
Innovation Solution
A lightweight PV assembly design featuring a support assembly with module registration members and mounting elements that secure PV modules to a base, allowing for flexible positioning and reduced weight, along with wind deflectors and ballast to counteract wind forces without penetrating the roof, enabling easy installation and reduced material usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If heavy ballast is used to counteract wind uplift forces, then the PV assembly stability is improved, but the weight of the PV assembly increases
Solution Approach 1:
The patent uses ballast as a counterweight to resist wind uplift forces acting on the PV assembly. The ballast is positioned on the roof surface to provide downward force that counteracts the upward wind loads, allowing the assembly to remain stable without penetrating the roof membrane.
Solution Approach 2:
The PV assembly is divided into separate functional components: PV modules, support structure, and ballast. This segmentation allows the ballast to be independently positioned and adjusted to optimize wind resistance while keeping the overall assembly lightweight and easy to install.
2Stability of the object's composition
If penetrating fasteners are used to secure PV modules, then the PV assembly stability is improved, but the roof membrane integrity is compromised
Solution Approach 1:
The patent extracts the fastening function from the roof membrane by using non-penetrating support structures and ballast. Instead of fasteners that pierce the membrane, the system uses surface-mounted components that secure the PV assembly without compromising the waterproof integrity of the roof.
Solution Approach 2:
The support structure acts as an intermediary between the PV modules and the roof surface. It provides mechanical support and stability while distributing loads without penetrating the membrane, thus mediating between the need for secure attachment and the need to preserve roof integrity.
3Ease of manufacture
If lightweight materials are used for PV assembly, then the transport and installation cost is reduced, but the wind uplift resistance is decreased
Solution Approach 1:
The patent employs ballast as a counterweight to compensate for the lightweight construction. The ballast provides the necessary downward force to resist wind uplift, allowing the use of lightweight materials for the PV modules and support structure without compromising wind resistance.
Solution Approach 2:
The system changes the mass distribution parameters by concentrating weight in the ballast components rather than throughout the entire assembly. This allows the PV modules and support structure to remain lightweight for easy handling, while the ballast provides the necessary weight for wind resistance.
4Force
If multiple components are used to reduce wind uplift, then the wind resistance is improved, but the device complexity increases
Solution Approach 1:
The PV assembly is segmented into distinct functional components: PV modules, support structures, and ballast. This segmentation allows each component to be optimized independently and simplifies installation, as components can be assembled in a straightforward sequence without complex interconnections.
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 solution reduces the need for heavy ballast and roof penetrations, lowers installation costs, and allows for simpler, more efficient transport and installation of PV modules, while maintaining the integrity of the roof and reducing wind uplift forces, thus enhancing the overall efficiency and cost-effectiveness of PV installations.
Implementation Method 1
a thermal expansion and contraction movement-accommodating joint securing the support pad to the base. This permits relative movement between the base and the pad in at least one direction parallel to the lower surface of the base.
Data Source
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AI summary
A supported PV assembly may include a PV module comprising a PV panel and PV module supports including module supports having a support surface supporting the module, a module registration member engaging the PV module to properly position the PV module on the module support, and a mounting element. In some embodiments the PV module registration members engage only the external surfaces of the PV modules at the corners. In some embodiments the assembly includes a wind deflector with ballast secured to a least one of the PV module supports and the wind deflector. An array of the assemblies can be secured to one another at their corners to prevent horizontal separation of the adjacent corners while permitting the PV modules to flex relative to one another so to permit the array of PV modules to follow a contour of the support surface.