Solar panel flat roof mounting apparatus and method
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Solution Overview
Problem
Conventional solar photovoltaic systems require roof penetration for anchoring, which compromises sealing integrity and increases installation costs, and may need frequent reinstallation due to roof replacement or damage, affecting system economics.
Innovation Solution
A rooftop mounting frame system that allows for minimal or no penetration, utilizing a grid of parallel and perpendicular struts with brackets to hold solar panels, reducing wind loads and requiring less ballast, and allowing for adjustable panel angles to maximize energy capture.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If roof-penetrating anchoring systems are used to secure solar panels, then the solar panels can be firmly anchored to withstand high winds and environmental elements, but the sealing integrity of the roof is compromised and installation costs increase
Solution Approach 1:
The patent extracts the anchoring function from the roof-penetration method and relocates it to a ballasted mounting system that rests on the roof surface without penetration. The anchoring strength is achieved through the weight of ballast elements and friction against the roof surface rather than mechanical penetration, thereby preserving roof sealing integrity while maintaining secure attachment.
Solution Approach 2:
The patent introduces ballast elements as intermediary components between the mounting structure and the roof surface. These ballast elements provide the necessary anchoring force through their weight and frictional contact, eliminating the need for direct penetration into the roof structure and thus preserving the roof's sealing integrity while achieving secure mounting.
2Strength
If multiple anchor points with penetration are used throughout the roof, then the solar system can be securely anchored, but installation costs significantly increase
Solution Approach 1:
The patent removes the need for multiple penetration anchor points by replacing them with a distributed ballasted mounting system. The anchoring function is achieved through the cumulative effect of multiple ballast elements distributed across the mounting structure, eliminating costly penetration work while maintaining secure anchoring through friction and weight.
Solution Approach 2:
The patent employs relatively simple, inexpensive ballast elements that can be easily installed and adjusted compared to costly penetration anchor systems. These ballast elements provide sufficient anchoring through their weight and friction, offering a cost-effective alternative to multiple expensive penetration points while maintaining system security.
3Strength
If roof-penetrating anchoring systems are installed, then the solar system can be securely mounted, but frequent reinstallation is required when roof replacement or damage occurs, affecting system economics
Solution Approach 1:
The patent extracts the mounting system from the roof structure by eliminating penetration points. The ballasted mounting system rests on the roof surface without becoming permanently integrated through penetration, allowing the solar system to be easily relocated or reinstalled when roof replacement or damage occurs, thereby extending the operational lifespan of the solar investment.
Solution Approach 2:
The patent creates a dynamic, adaptable mounting system using ballast elements that can be easily repositioned and reconfigured. This flexibility allows the solar system to accommodate roof replacements or damage without permanent attachment, enabling the system to adapt to changing roof conditions and extend its operational lifespan through easy reinstallation.
Data Source
AI summary
A roof-mounted solar energy apparatus including a mounting frame having a plurality of struts positioned in a first direction, the plurality of struts substantially parallel to one another, and a plurality of cross-member struts positioned in a second position that is substantially perpendicular to the plurality of struts positioned in the first direction. The plurality of struts attached to the crossmember struts. The apparatus also including a bracket having an end for engaging a strut or a cross-member strut and dimensioned to hold a solar panel. The solar panel or panels are held at an angle with respect to the flat roof or with respect to the struts. A method of forming a solar energy apparatus includes laying a plurality of struts in a first orientation, the plurality of struts being substantially parallel to one another, and attaching at least one crossmember to the plurality of struts to form a frame.