Ballasted PV Module Support Members for Non-Penetrating Rooftop Mounting

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Solution Overview

Problem

Existing mounting systems for photovoltaic modules are not environmentally friendly, are costly, time-consuming to install, and can damage rooftops by penetrating the roof membrane, and require customization for each type or brand of PV module.

Innovation Solution

A mounting system comprising separate support members that securely position photovoltaic modules without penetrating the rooftop, using ballast for weight distribution and integrated grounding, allowing for universal application with any PV module width and length, and featuring a plastic design that is recyclable and non-corrosive.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If traditional mounting systems are used to secure PV modules to rooftops, then wind load resistance is adequate, but the roof membrane is damaged by penetration

Engineering Contradiction:

Improvewind load resistanceVSAvoidroof membrane damage

Core Design Contradiction:

StrengthVSObject-affected harmful factors

Solution Approach 1:

The patent introduces an intermediary mechanism (ballast-weighted support structure) that transfers wind loads to the roof surface without penetration. The ballast weights provide downward force to counteract uplift winds, while the support members distribute loads across the roof membrane, eliminating the need for penetrating fasteners and thus preventing roof damage.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The patent replaces the traditional mechanical penetration system (screws, bolts, or clips that pierce the roof) with a non-penetrating ballast-based anchoring system. The mechanical function of securing the array against wind loads is achieved through gravity-based ballast weights rather than intrusive fasteners, substituting a non-destructive mechanical approach for a destructive one.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Manufacturing precision

If custom fabricated mounting systems are used for each type or brand of PV module, then module-specific fit is optimized, but production cost increases

Engineering Contradiction:

Improvemodule-specific fitVSAvoidproduction cost

Core Design Contradiction:

Manufacturing precisionVSEase of manufacture

Solution Approach 1:

The patent designs universal support members and ballast components that can accommodate multiple PV module types, sizes, and brands through adjustable positioning mechanisms and standardized interfaces. This single standardized system replaces the need for custom-fabricated mounting solutions for each module type, reducing manufacturing complexity and cost while maintaining adequate fit and support.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Reliability

If traditional mounting systems are used, then secure attachment is achieved, but installation time increases

Engineering Contradiction:

Improvesecure attachmentVSAvoidinstallation time

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The patent segments the mounting system into modular, pre-fabricated components (support members, ballast weights, connection interfaces) that can be independently assembled and configured. This modular approach allows for rapid assembly compared to traditional systems that require on-site fabrication or complex integration, reducing installation time while maintaining secure attachment through standardized connection mechanisms.

Inventive Principle:

Principle #1Segmentation

4Object-affected harmful factors

If environmentally friendly mounting systems are used, then environmental impact is reduced, but structural strength may be compromised

Engineering Contradiction:

Improveenvironmental impactVSAvoidstructural strength

Core Design Contradiction:

Object-affected harmful factorsVSStrength

Solution Approach 1:

The patent employs composite construction combining durable, environmentally benign materials such as recycled plastics, composite polymers, and sustainably sourced metals for the support members and ballast structures. These composite materials provide sufficient structural strength to withstand wind loads and support PV module weights while being non-corrosive, recyclable, and environmentally friendly, replacing traditional metal systems that are prone to corrosion and difficult to recycle.

Inventive Principle:

Principle #40Composite materials

Data Source

PatentUS9196755B2Support member for mounting photovoltaic modules and mounting system including the same

Publication Date: 2015.11.24 UNIRAC INC

AI summary

A support member for mounting photovoltaic modules on a support surface and a mounting system including the same are disclosed herein. The support member may comprise a body portion that includes a ballast receiving portion for accommodating one or more ballasts, the body portion further including a first support portion with a first surface and a second support portion with a second surface, the first support portion being spaced apart from the second support portion by the ballast receiving portion. The support member is configured to bridge a plurality of rows of photovoltaic modules, the first surface of the support member configured to support one or more photovoltaic modules in a first row of the plurality of rows of photovoltaic modules, and the second surface of the support member configured to support one or more photovoltaic modules in a second row of the plurality of rows of photovoltaic modules.