Ballasted PV Module Support Assembly for Wind-Resistant Roof Mounting
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Solution Overview
Problem
Existing solar mounting systems for photovoltaic modules are complex, expensive, and difficult to install, with many separate parts that require time-consuming assembly and do not easily adapt to uneven roof surfaces or conform to wind loads effectively.
Innovation Solution
A support assembly for photovoltaic modules that includes a ballast tray, tubular members, and clamp members, which are designed to be easily assembled, adjustable, and nestable for efficient shipping and installation, with features such as visual and tactile indicia for mounting locations and serrated edges for wind resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If prior mounting systems use many separate parts to withstand wind loads and avoid roof penetration, then reliability is improved, but device complexity and ease of manufacture deteriorate
Solution Approach 1:
The patent combines multiple separate components into an integrated support assembly that includes a support member, clamp member, and ballast tray as a unified structure. This merging reduces the number of separate parts while maintaining the ability to withstand wind loads through the integrated design, directly resolving the contradiction between reliability and device complexity.
Solution Approach 2:
The support assembly is designed to perform multiple functions simultaneously: it provides structural support, resists wind loads, adjusts to uneven surfaces, and eliminates the need for roof penetration. This multi-functionality allows a single integrated structure to replace multiple specialized components, reducing complexity while maintaining reliability.
2Strength
If prior mounting systems use many separate parts to ensure structural integrity, then strength is improved, but ease of operation and installation time deteriorate
Solution Approach 1:
The support assembly is pre-configured with the support member, clamp member, and ballast tray integrated together before installation. This preliminary assembly eliminates the need for complex on-site assembly of multiple separate parts, maintaining structural integrity while significantly improving installation speed and ease of operation.
Solution Approach 2:
The support member includes features that allow it to adapt dynamically to uneven roof surfaces during installation. This dynamic capability enables the pre-assembled unit to conform to various surface conditions without requiring additional adjustment components, maintaining strength while simplifying the installation process.
3Adaptability or versatility
If prior mounting systems use multiple components to accommodate uneven roof surfaces, then adaptability is improved, but device complexity and shipping efficiency deteriorate
Solution Approach 1:
The support member is designed with dynamic characteristics that allow it to flex and adapt to uneven roof surfaces. This inherent adaptability is built into the single integrated structure rather than requiring multiple adjustable components, maintaining versatility while reducing device complexity.
Solution Approach 2:
The clamp member is designed to nest within or attach to the support member, and the ballast tray integrates with these components. This nesting arrangement allows the entire adaptable assembly to collapse into a compact form for efficient shipping, maintaining adaptability to uneven surfaces while reducing shipping volume and complexity.
4Reliability
If prior mounting systems use many separate parts and components, then reliability is improved, but loss of time in assembly and shipping costs deteriorate
Solution Approach 1:
By merging the support member, clamp member, and ballast tray into an integrated assembly, the patent reduces the number of parts that need to be handled, transported, and assembled separately. This maintains mounting system reliability while significantly reducing assembly time and shipping logistics time.
Solution Approach 2:
The support assembly is pre-integrated at the manufacturing stage, performing the assembly action beforehand. This preliminary action eliminates time-consuming on-site assembly of multiple components and reduces shipping complexity, directly addressing the loss of time in assembly and logistics while maintaining system reliability.
Data Source
AI summary
A support assembly for supporting one or more photovoltaic modules on a support surface, such a generally flat roof, is disclosed herein. The support assembly includes a ballast tray configured to accommodate one or more ballasts; at least one tubular member coupled to the ballast tray, the at least one tubular member configured to support one or more photovoltaic modules above a support surface; and at least one clamp member coupled to the at least one tubular member. In one or more embodiments, the support assembly further includes at least one channel member coupling said at least one tubular member to said ballast tray. A mounting system including a plurality of support assemblies is also disclosed herein.