Ballasted Solar Panel Mounting Base With 5–10° Angle Selection
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Solution Overview
Problem
Existing solar panel racking systems face challenges in meeting strength, reliability, and safety standards while allowing for easy installation and adjustable angles, especially when non-permanent connections are desired, and often require complex adjustment components or compromise on optimal angle settings.
Innovation Solution
A solar panel mounting system featuring injection-molded bases with multiple connection locations and adjustable clamps, allowing for flexible angle adjustments from 5 to 10 degrees, and using ballast blocks for non-invasive installation, enabling quick and easy installation without the need for permanent structural penetration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If ballast-based racking systems are used for non-permanent installation, then ease of removal and minimal surface penetration is achieved, but strength, reliability, and ability to meet safety standards deteriorates
Solution Approach 1:
The mounting system is divided into separate components: a base that contacts the roof surface, vertical posts, and attachment clamps. This segmentation allows the base to provide stable support through its footprint while the posts and clamps provide secure panel attachment, achieving both ease of removal and structural reliability.
Solution Approach 2:
The base is designed with pre-determined geometric features including attachment wells positioned at specific locations and angles. These preliminary design decisions enable reliable panel mounting at optimal angles without requiring complex field adjustments, while maintaining simple installation and removal procedures.
2Adaptability or versatility
If complicated adjustment components are used to achieve desired panel angles, then adaptability to different installation locations is improved, but device complexity increases
Solution Approach 1:
Different attachment wells are positioned at specific locations and orientations on the base to accommodate various panel angles and installation configurations. This local differentiation of attachment point qualities provides adaptability without requiring complex adjustable mechanisms.
Solution Approach 2:
The system provides fixed attachment wells at predetermined angles (including 5 and 10 degrees) that allow dynamic selection of the optimal mounting angle based on installation requirements, achieving adaptability through discrete angular options rather than continuous adjustment mechanisms.
3Reliability
If permanent structural penetration is used to secure solar panels, then strength and reliability are improved, but ease of removal and minimal surface penetration deteriorates
Solution Approach 1:
The base acts as an intermediary component between the roof surface and the solar panel mounting system. It provides stable support through its geometric footprint and weight distribution without penetrating the roof structure, while still enabling secure panel attachment through its attachment wells and compatible clamps.
Data Source
AI summary
A solar panel mounting base and system for solar panel installation uses a mounting base that is injection molded to include different connection locations which provide flexibility when installing solar panels to the mounting bases. Attachment clamps are secured to the mounting base using carriage bolts which are secured to the mounting base in an attachment well and allow the installer to attach solar panels from the top which makes installation easy and fast. The attachment clamps have a horizontal and vertical portion that use grooves to adjustably secure the two together when in the desired location. Ballast blocks are used to provide a non-invasive installation. In an array, multiple bases are used to provide the structure to support the solar array. Installers may vary the angle the solar panels form 5 degrees to 10 degrees by selecting the appropriate connection location.