Fastening system
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Solution Overview
Problem
Existing fastening systems for solar panels or photovoltaic modules on roofs face challenges in preventing water penetration and are complex, expensive, and prone to assembly complications due to porous rubber sleeves and loose cable ties, which can lead to water infiltration.
Innovation Solution
A fastening system with a base element and cover plate that uses self-tapping screws for easy assembly, featuring conical beads for alignment and sealing, and an optional sealing material like EPDM for enhanced waterproofing, eliminating the need for a recess for a roof hook and creating a labyrinth seal to prevent water ingress.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If a rubber sleeve is used to cover the mounting area, then water penetration is initially prevented, but the rubber sleeve becomes porous over time due to UV radiation allowing water to penetrate
Solution Approach 1:
The invention removes the rubber sleeve component entirely from the system. Instead of using a rubber sleeve that degrades under UV radiation, the patent employs a metal cover plate with integrated sealing features (beads/conical protrusions) that work with the fastening elements to create a durable waterproof seal without relying on UV-sensitive materials.
Solution Approach 2:
The invention uses a composite sealing approach combining metal beads (structural component) with an elastomeric sealing element (sealing component). This composite system leverages the UV resistance and structural integrity of metal while incorporating elastomeric material specifically for its sealing properties, creating a more reliable long-term solution than rubber alone.
2Object-affected harmful factors
If a cable tie is used to secure the rubber sleeve to the roof hook, then initial sealing is achieved, but the cable tie loosens and becomes brittle over time allowing water penetration
Solution Approach 1:
The invention eliminates the cable tie component from the system. The sealing mechanism is integrated into the cover plate and fastening elements themselves through beads and corresponding recesses, removing the need for separate fastening components that can loosen or degrade over time.
Solution Approach 2:
The invention combines the sealing function and the fastening function into a single integrated system. The beads on the cover plate serve both as alignment features and as integral parts of the sealing mechanism, while the fastening elements simultaneously secure the cover plate and maintain the seal, eliminating the need for separate cable ties.
3Ease of operation
If a recess is provided for inserting a roof hook, then the mounting rail can be attached, but the recess creates a pathway for water to penetrate into the roof
Solution Approach 1:
The invention uses the elastomeric sealing element (seal ring) as a flexible component that deforms to create an effective seal around the fastening elements and beads. This flexible seal maintains waterproofing while allowing the necessary mechanical fastening function to occur through the same opening.
Solution Approach 2:
The invention adds a vertical dimension to the sealing approach by using beads that protrude upward from the cover plate surface and corresponding recesses in the fastening elements. This creates a multi-level sealing system where the seal operates in the vertical dimension (around the beads and fasteners) rather than just a flat plane, preventing water from penetrating through the mounting opening.
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 allows for quick, simple, and secure installation of mounting rails while effectively preventing water penetration, ensuring a reliable seal and stability on the roof, even under varying loads like snow.
Implementation Method 1
The sealing material can be firmly connected to the fastening element, for example glued. The sealing effect between the fastening element and cover plate can be improved by the sealing material.
Implementation Method 2
Improved alignment or self-alignment during fastening between the base element and the fastening element can be achieved by compressing or deforming the sealing material to different degrees.
Data Source
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AI summary
The invention relates to a fastening system (1) for fastening a mounting rail (23) for a roof-mounted element, in particular a solar panel or photovoltaic module (24) on a roof of a building, comprising a base element (2) that can be fastened to a roof rafter (4) or beam, a fastening element (3) that can be detachably connected to the base element (2) for fastening the mounting rail, and a cover plate (12) that can be arranged between the base element and the fastening element for covering a fastening area of the roof, wherein the cover plate is held between the base element and the fastening element by the detachable connection of the base element with the fastening element.