Rail mounting apparatus, system and method of securing devices to a structure
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Solution Overview
Problem
Existing solar panel mounting systems face challenges with fasteners and nuts that can move along the rail or disengage during installation, leading to reduced safety and increased installation time due to the need for additional materials and complex assembly processes.
Innovation Solution
A rail mounting system utilizing a channel nut with a biasing element that securely engages with the rail's interior structures, featuring a recess and flange design, allowing for direct insertion and retention within the rail's channel, thereby simplifying the installation process and ensuring the panel's secure positioning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional fasteners and nuts are used to engage the rail, then the attachment system can be assembled, but the fasteners and nuts may move along the rail or disengage during installation
Solution Approach 1:
The attachment system is divided into distinct functional components: the rail with its channel structure, the channel nut with biasing element, and the fastener assembly. This segmentation allows each component to perform its specific function - the biasing element provides continuous engagement force while the fastener secures the final position, eliminating the problems of movement and disengagement
Solution Approach 2:
The biasing element is pre-loaded within the channel nut before installation, creating an initial engagement force as the nut is inserted into the rail channel. This preliminary action ensures the channel nut maintains continuous contact with the rail interior structures (tooth and shelf) throughout installation, preventing disengagement and improving reliability
2Reliability
If traditional fastener assemblies are used, then the rail can be secured, but additional installation time is required due to complex assembly processes
Solution Approach 1:
The channel nut integrates multiple functions into a single component: it provides the engagement mechanism with the rail channel, houses the biasing element for continuous contact, and interfaces with the fastener for final securing. This merging eliminates the need for separate adjustment and positioning steps required by traditional multi-component fastener assemblies, reducing installation time while maintaining security
Solution Approach 2:
The biasing element automatically maintains engagement between the channel nut and rail interior structures during the installation process. As the channel nut is inserted and positioned, the biasing element self-adjusts to apply continuous force against the tooth and shelf, eliminating the need for additional adjustment operations and reducing overall installation time
3Productivity
If traditional attachment systems are used, then the rail can be mounted, but reduced safety results due to fasteners moving or disengaging
Solution Approach 1:
The biasing element is pre-loaded in the channel nut to provide immediate engagement force upon insertion into the rail channel. This preliminary action ensures continuous contact with the rail's interior structures throughout the installation process, preventing the movement and disengagement issues that compromise safety in traditional systems
Solution Approach 2:
The biasing element acts as an intermediary between the channel nut and the rail's interior structures (tooth and shelf). It provides continuous mechanical contact and engagement force, ensuring the channel nut remains securely positioned on the rail during installation, thereby improving both safety and productivity
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The system enables quick and secure attachment of solar panels and other devices by allowing the channel nut to be positioned accurately along the rail, reducing installation time and enhancing safety through a simplified and efficient assembly process.
Implementation Method 1
a biasing element secured to the channel nut and configured to engage the sloped surface and push the channel nut against the interior structures of the rail
Data Source
AI summary
A retention apparatus, system and method of attaching items, panels or other devices to a rail formed in longitudinal lengths configured with a cross-sectional profile having multiple cooperating structures between the rail and a channel nut including a recess formed between a tooth and shelf on an interior first channel portion of the rail and a flange of the channel nut, between an anchor latch of the rail and hook flange on the channel nut, and cooperating forces and movement of the biasing element secured to the channel nut.