Ballasted PV Module Assembly for Non-Penetrating Rooftop Mounting

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Solution Overview

Problem

Conventional photovoltaic module installations on rooftops require labor-intensive processes and can cause damage due to the need for penetrating attachments and uneven ballast distribution, which affects wind resistance and long-term structural integrity.

Innovation Solution

A photovoltaic module assembly with a ballast tray that is removably associated with the module frame, allowing for non-penetrating installation and adjustable ballast distribution, minimizing the footprint and preventing upward displacement from the rooftop.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If PV modules are physically attached to the rooftop via bolts driven through the rooftop, then the PV module attachment strength is improved, but the rooftop is permanently damaged and water damage opportunities arise

Engineering Contradiction:

ImprovePV module attachment strengthVSAvoidrooftop damage and water damage risk

Core Design Contradiction:

StrengthVSObject-affected harmful factors

Solution Approach 1:

The patent removes the penetration method entirely from the attachment system. Instead of driving bolts through the rooftop, the system uses ballast weights that rest on the rooftop surface, completely eliminating holes and associated water damage risks while maintaining secure attachment through gravitational force

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent introduces ballast as an intermediary element between the PV module and the rooftop. The ballast serves as a mediator that provides attachment force without direct penetration, distributing the load through weight rather than mechanical fastening, thus protecting the rooftop structure

Inventive Principle:

Principle #24Intermediary (Mediator)

2Use of energy by moving object

If PV modules are tilted relative to the rooftop to optimize sunlight collection, then the solar energy collection efficiency is improved, but wind-generated forces increase and module displacement risk increases

Engineering Contradiction:

Improvesolar energy collection efficiencyVSAvoidwind-generated forces

Core Design Contradiction:

Use of energy by moving objectVSForce

Solution Approach 1:

The patent employs ballast weights as counterweights that oppose the uplift forces generated by wind acting on tilted PV modules. The ballast creates a downward force that balances the aerodynamic lift, allowing the modules to maintain their optimal tilted orientation while resisting wind-induced displacement

Inventive Principle:

Principle #8Anti-weight (Counterweight)

Solution Approach 2:

The patent creates a dynamic equilibrium system where the ballast weight provides a constant downward force that adapts to varying wind conditions. The system naturally balances forces without active control, allowing the tilted modules to maintain stability across different wind speeds and directions

Inventive Principle:

Principle #15Dynamics

3Force

If ballast is mounted to PV modules using direct on-site mounting, then the wind resistance is improved, but the installation process becomes labor-intensive and time-consuming

Engineering Contradiction:

Improvewind resistanceVSAvoidinstallation time

Core Design Contradiction:

ForceVSLoss of time

Solution Approach 1:

The patent incorporates ballast mounting features during the PV module manufacturing process rather than requiring on-site assembly. The ballast trays and attachment mechanisms are pre-integrated into the module structure, allowing installers to simply place the modules with ballast already positioned, dramatically reducing installation time while maintaining wind resistance

Inventive Principle:

Principle #10Preliminary action

4Force

If ballast weight is increased to improve wind performance, then the wind resistance is improved, but the stress on the PV module frame increases

Engineering Contradiction:

Improvewind resistanceVSAvoidframe stress

Core Design Contradiction:

ForceVSStress or pressure

Solution Approach 1:

The patent divides the ballast system into multiple separate ballast units distributed across the PV module array rather than using a single large ballast. This segmentation distributes the total weight across multiple attachment points, reducing the stress concentration on any single frame location while maintaining overall wind resistance through cumulative ballast effect

Inventive Principle:

Principle #1Segmentation

Data Source

PatentUS8065844B2Ballasted photovoltaic module and module arrays

Publication Date: 2011.11.29 TOTALENERGIES ONETECH

AI summary

A photovoltaic (PV) module assembly including a PV module and a ballast tray. The PV module includes a PV device and a frame. A PV laminate is assembled to the frame, and the frame includes an arm. The ballast tray is adapted for containing ballast and is removably associated with the PV module in a ballasting state where the tray is vertically under the PV laminate and vertically over the arm to impede overt displacement of the PV module. The PV module assembly can be installed to a flat commercial rooftop, with the PV module and the ballast tray both resting upon the rooftop. In some embodiments, the ballasting state includes corresponding surfaces of the arm and the tray being spaced from one another under normal (low or no wind) conditions, such that the frame is not continuously subjected to a weight of the tray.