Corrugated Panel Mounting Bracket for Non-Penetrating PV Attachment
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Solution Overview
Problem
Existing methods for installing structures on standing seam metal panels often puncture the panels, leading to costly repairs, leakage, and corrosion issues, and are not suitable for mounting photovoltaic systems efficiently.
Innovation Solution
A mounting bracket designed for corrugated panels with panel valley and crown engagement sections that securely attach to the panels without puncturing, allowing for the installation of photovoltaic systems without damaging the panels, using a one-piece construction and extrusion design that spans the length of the panel's crowns and valleys.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If puncturing methods are used to install structures on standing seam metal panels, then the installation process is simplified and structures can be securely mounted, but the panels suffer from leakage, corrosion, and costly repairs
Solution Approach 1:
The mounting bracket acts as an intermediary component between the photovoltaic system and the corrugated panel. It engages with the panel's crown and valley structures through non-penetrative contact, transferring mechanical loads without puncturing the panel surface, thus maintaining panel integrity while enabling secure structure mounting
Solution Approach 2:
The mounting bracket is divided into distinct functional sections: a panel crown engagement section with first and second engagement portions that interface with the panel crown, and a panel valley engagement section with third and fourth engagement portions that interface with the panel valley. This segmentation allows each section to independently engage different structural features of the corrugated panel, distributing mounting forces across multiple contact points without penetration
2Reliability
If standing seam panels are used to define building surfaces, then the aesthetic appearance and structural integrity are improved, but the cost of the building surface increases significantly
Solution Approach 1:
The mounting bracket is designed to be universally applicable to corrugated panels with standard crown and valley dimensions. The engagement sections can accommodate variations in panel specifications within standard ranges, allowing the same bracket design to be used across different building surfaces without requiring custom solutions, thereby reducing overall building costs while maintaining panel integrity
3Productivity
If photovoltaic systems are installed on building roofs, then renewable energy generation is enabled, but the installation process may damage the roofing surface
Solution Approach 1:
The mounting bracket serves as a mediator between the photovoltaic system weight and the corrugated panel structure. It distributes the mechanical loads from the photovoltaic mounting rails across the panel's crown and valley features through non-penetrative engagement, enabling renewable energy installation without causing roofing surface damage
Solution Approach 2:
The bracket design utilizes the flexibility and structural properties of the corrugated panel's thin metal sheets. The engagement portions are shaped to conform to the panel's crown and valley profiles, allowing the bracket to flex slightly with thermal expansion and contraction of the panel while maintaining secure non-penetrative contact, thus protecting the panel from damage
Data Source
AI summary
A mounting bracket (210) for a corrugated panel (202) is disclosed. The mounting bracket (210) includes an upper wall (216) in the form of an at least substantially flat surface for supporting various types of attachments. This upper wall (216) is disposed above and spaced from a panel valley engagement section (232) for engaging a panel valley (208) of the corrugated panel (202). A panel crown engagement section (224) is positioned on each side of the panel valley engagement section (232) for engaging different panel crowns (204) of a corrugated panel (202). An attachment may be secured relative to the mounting bracket (210) utilizing a mounting hole (218) on the bracket upper wall (216).