Height-adjustable rail-less solar panel mounting device for roofs
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Solution Overview
Problem
Rail-less solar panel mounting systems face challenges in leveling and adjusting the position of solar panels on uneven roof surfaces without the support of rails, complicating the installation process and increasing installation time.
Innovation Solution
A solar panel mounting assembly that includes a base, slider, platform, height adjuster, and threaded locking fastener, allowing for upward adjustment of the solar panel height and position, with the height adjuster and locking fastener oriented for easy access from above, enabling adjustment of the solar panel's height, angle, and position even after installation, and restricting movement to one degree of freedom to prevent rotation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a rail-based system is used, then the solar panels can be leveled and positioned easily, but the system complexity and installation cost increase
Solution Approach 1:
The patent removes the rail component from the mounting system entirely. Instead of using a continuous rail that spans the length of solar panels, the invention uses discrete mounting devices with adjustable brackets that attach directly to the roof structure. This extraction of the rail element simplifies the overall system while maintaining the ability to level and position panels through the adjustable bracket mechanism.
Solution Approach 2:
The patent divides the continuous rail system into discrete, segmented mounting devices. Each mounting device is an independent unit with its own adjustment capabilities, allowing panels to be leveled and positioned without requiring a continuous rail structure. This segmentation reduces system complexity while preserving the essential leveling function.
2Device complexity
If a rail-less system is used, then the system complexity is reduced, but the ability to level and adjust solar panels on uneven roofs deteriorates
Solution Approach 1:
The patent incorporates dynamic adjustment capabilities into the mounting devices. The brackets include slots and adjustment mechanisms that allow installers to modify the height, angle, and position of each mounting device independently. This dynamic adjustability compensates for the absence of rails, enabling proper leveling and positioning of solar panels on uneven roof surfaces while maintaining a simple, rail-less system architecture.
3Loss of time
If adjustment mechanisms are made accessible from above, then installation time is reduced, but the mechanical complexity of the adjustment mechanisms increases
Solution Approach 1:
The patent inverts the traditional adjustment mechanism orientation. Instead of requiring access from the side or below the mounting device, the adjustment mechanisms are designed to be accessible from above. This is achieved by positioning the adjustment components on the upper surface of the mounting device, allowing installers to make adjustments without needing to access difficult-to-reach areas, thereby reducing installation time despite the added mechanical complexity.
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
Simplifies the installation process, reduces installation time, and enhances the stability of the solar panel mounting system by allowing for precise adjustment of the solar panels' height and position without the need for rails, improving operational efficiency.
Implementation Method 1
A threaded locking fastener can lock the slider assembly. Like the height adjuster, the threaded locking fastener is upwardly oriented so it can be adjusted from above.
Implementation Method 2
The height adjuster is oriented upwardly so the adjustment can be made from above. The height adjuster and the threaded locking fastener can be positioned proximate to the centerline on opposite sides of the platform.
Data Source
AI summary
A solar panel mounting device can secure solar panels to roof structures. The solar panel mounting device allows for position adjustment lengthwise along a base via a threaded locking fastener. The base being mountable to a roof surface either directly or optionally via flashing. In addition, the height of a platform that can be used to seat one or more solar panels can be adjusted relative to the roof surface. The solar panel mounting device is so structured so that both the locking fastener and the height adjuster can be accessed from above the solar panels. This allows for both position and height adjustment after the solar panels are installed.