Flexible PV Module Mounting on Ribbed Roofs
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Solution Overview
Problem
Existing systems for mounting flexible photovoltaic modules on rooftops face issues such as increased operational temperature, water intrusion, and labor-intensive installation, particularly on ribbed metal rooftops, where direct attachment can cause undesirable alterations and water incursion.
Innovation Solution
A mounting system comprising elongate brackets with flanges that define channels, allowing flexible PV modules to be securely attached and easily removable from ribbed rooftops, using standoff members to prevent water intrusion and ridge caps to resist wind uplift, without requiring extensive rooftop modifications.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If flexible PV modules are directly mounted to rooftops, then installation simplicity is improved, but operational temperature increases and water intrusion risk worsens
Solution Approach 1:
The patent introduces mounting brackets as intermediary components between the PV module and rooftop. These brackets create an air gap that serves as a thermal mediator, reducing heat transfer from the rooftop to the module while maintaining simple installation through standardized attachment points.
Solution Approach 2:
The mounting system segments the attachment function into separate components: rooftop-mounted brackets and module-mounted brackets. This segmentation allows the module to be mounted without direct rooftop contact, reducing temperature while keeping installation simple through modular assembly.
2Ease of operation
If flexible PV modules are directly attached to rooftops with fasteners, then installation ease is improved, but water incursion into the building worsens
Solution Approach 1:
The mounting brackets act as intermediary elements that prevent direct penetration of the rooftop membrane. Fasteners attach to the brackets rather than penetrating the roof, eliminating the water intrusion pathway while maintaining secure attachment.
Solution Approach 2:
The attachment system separates the fastening function (performed by brackets) from the roof penetration function (eliminated). This segmentation allows installation ease through standardized bracket attachment while preventing water incursion by avoiding roof membrane penetration.
3Reliability
If solar module mounting structures are used, then protection from water intrusion and temperature increase is improved, but cost and installation time worsen
Solution Approach 1:
The patent uses simple L-shaped or U-shaped brackets as intermediaries instead of complex mounting structures. These basic geometric forms provide adequate protection while minimizing device complexity and material usage.
Solution Approach 2:
The mounting brackets utilize the existing ribbed structure parameters of the rooftop (rib spacing, rib height) to determine bracket dimensions and placement. This parameter matching simplifies the bracket design to fit standard rooftop configurations without requiring custom complex structures.
4Reliability
If mounting structures are used to protect PV modules, then reliability is improved, but labor intensity and installation time worsen
Solution Approach 1:
The mounting system is segmented into pre-fabricated bracket units that can be quickly attached to existing rooftop ribs. This segmentation eliminates the need for custom fabrication and complex assembly, improving installation speed while maintaining protection reliability.
Solution Approach 2:
The mounting brackets are designed to be pre-positioned on the rooftop ribs before module attachment. This preliminary action simplifies the overall installation process, allowing workers to quickly secure modules without complex structural assembly, thereby improving productivity while ensuring reliable protection.
Data Source
AI summary
A system for mounting flexible photovoltaic (PV) modules on ribbed rooftops (e.g., purlin bearing rib-style roofs) may include a pair of mating mounting brackets, one affixed to the PV module and the other affixed to a rib of the roof. The PV module may have a concave-down profile when installed, with standoffs installed on a bottom side of the module and hold-down ridge caps installed on adjacent ribs of the roof.