Bracket Mount with Threaded Flashing for Solar Panel Rail Installation
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Solution Overview
Problem
The installation of solar panel arrays on shingle roofs is arduous due to the limitations of traditional L-Foot connection brackets, which are difficult to install and do not effectively prevent water leakage, and there is a need for a more efficient and symmetrical bracket that can secure solar panel rail guides and rail-less pivot mounts.
Innovation Solution
A novel bracket with a cylindrical base, U-shaped guide, and recessed path with a lip to secure rail guides with a nut and bolt, combined with a sealed flashing system using an internal threaded connection and tactile snap for easy installation and enhanced water protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional L-Foot connection brackets are used to secure solar panel rail guides on shingle roofs, then the installation can be completed, but the installation process becomes arduous and time-consuming
Solution Approach 1:
The bracket is divided into distinct functional segments: a base portion that interfaces with the rail guide, a flashing portion that integrates with roof shingles, and a connection mechanism. This segmentation allows each component to be optimized independently and simplifies the overall installation process by making the bracket easier to handle and position.
Solution Approach 2:
The bracket is designed with pre-formed geometric features including angled surfaces, positioning ribs, and integrated flashing elements that are shaped during manufacturing. These preliminary actions eliminate the need for field modifications or complex assembly steps, allowing installers to simply position and secure the bracket without additional fabrication work.
2Reliability
If L-Foot brackets are used to mount solar panel rail guides, then the mounting function is achieved, but water leakage protection is insufficient
Solution Approach 1:
The bracket merges the mounting function with the waterproofing function into a single integrated component. The flashing portion of the bracket directly interfaces with roof shingles to create a water diversion path, while the base portion secures the rail guide. This combination eliminates the need for separate waterproofing measures and ensures reliable water leakage protection.
Solution Approach 2:
The flashing portion acts as an intermediary element between the bracket base and the roof shingles. It creates a protective barrier that diverts water away from the penetration point where the rail guide passes through the roof, preventing water leakage without adding complex multi-layer waterproofing systems.
3Adaptability or versatility
If traditional L-Foot brackets are used, then basic mounting is possible, but the bracket cannot be easily adjusted or repositioned
Solution Approach 1:
The bracket incorporates geometric features that allow for adjustable positioning of the rail guide. The base portion includes surfaces and features that enable the rail guide to be positioned at different locations along the bracket while maintaining secure attachment. This dynamic adaptability allows installers to accommodate variations in rail guide positioning requirements without requiring custom-manufactured brackets.
4Ease of operation
If L-Foot brackets are installed on shingle roofs, then the rail guides can be secured, but the installation process requires special tools and is difficult to complete
Solution Approach 1:
The bracket is designed with self-aligning geometric features including angled surfaces, positioning ribs, and integrated flashing elements that guide the installer through the positioning process. The bracket's geometry naturally directs the rail guide into the correct position and ensures proper alignment with roof shingles, eliminating the need for special alignment tools or complex installation procedures.
Data Source
AI summary
In various representative aspects, an assembly for securing a solar panel rail and rail-less support structures to a shingle roof. More specifically, the apparatus includes a connection bracket and flashing device for use in installing solar panel rail support structures. The connection bracket is secured to the flashing device by rotating its base around a threaded connection until it locks in place so that a solar panel rail support guide can be connected to a generally U-shaped connection on the top of the bracket. The apparatus also offers an improved means to cover the penetration point on the flashing to protect it and prevent water from leaking into the roof as well as an improved way to install the apparatus over existing products. An alternate embodiment of the apparatus is offered to support a rail-less pivot mount as well.