Surface mount assemblies for a solar panel system
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Solution Overview
Problem
Solar panel systems face challenges in achieving level installations due to uneven installation surfaces and physical differences among solar modules, necessitating height-adjustable surface mount assemblies to ensure proper alignment and support.
Innovation Solution
The development of height-adjustable surface mount assemblies that include a base, track, fastener assembly, and threaded components, allowing for adjustable suspension of solar modules above the installation surface, with features like raised apertures and flanges for secure attachment and alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If surface mount assemblies are used to mount solar modules on uneven installation surfaces, then the solar modules can be installed, but the installation cannot achieve proper level alignment
Solution Approach 1:
The surface mount assembly incorporates height-adjustable mechanisms that allow the mounting structure to dynamically adapt to uneven installation surfaces. The adjustable height feature enables the assembly to maintain proper level alignment regardless of surface variations, resolving the contradiction between achieving precision alignment and adapting to varying conditions.
Solution Approach 2:
The invention changes the height parameter of the mount assembly to accommodate different surface elevations. By providing adjustable height settings, the system can compensate for uneven surfaces while maintaining proper alignment, thus improving manufacturing precision without sacrificing adaptability.
2Adaptability or versatility
If fixed-height surface mount assemblies are used, then the device structure is simple, but the assemblies cannot accommodate physical differences between solar modules
Solution Approach 1:
The mount assembly incorporates adjustable height mechanisms that allow it to adapt to physical differences between solar modules. This dynamic adjustment capability enables the system to accommodate module variations without requiring completely different mounting solutions for each module, balancing adaptability with manageable complexity.
Solution Approach 2:
The invention creates a universal mounting solution that can handle multiple scenarios - different surface elevations and various module physical characteristics - through a single adjustable assembly design. This multi-functionality reduces the need for multiple specialized components, managing overall system complexity while improving adaptability.
3Manufacturing precision
If height-adjustable mechanisms are added to surface mount assemblies, then proper level installation can be achieved, but the assembly complexity increases
Solution Approach 1:
The height-adjustable mechanism provides the necessary precision for level installation by allowing dynamic adjustment of mount height. The design incorporates practical adjustment features that achieve the desired precision without excessive complexity, balancing the two competing requirements.
Solution Approach 2:
The invention adjusts the height parameter through a controlled mechanism that provides sufficient precision for level installation. By implementing a practical adjustment system rather than an overly complex one, the solution achieves manufacturing precision while keeping device complexity at acceptable levels.
Data Source
AI summary
Surface mount assemblies for mounting to a solar panel frame to an installation surface are disclosed. In some embodiments, a base is coupled to a height-adjustable rail mount to slidably couple a track with a fastener assembly that includes of a fastener, spacer, and nut. In some embodiments, a base is coupled to a rail mount and positioned on a base plate to slidably couple to a surface track with a fastener assembly that includes a first fastener slidably coupled to a groove formed by the track, spacer, and second fastener. In some embodiments, a base is coupled to a rail mount for slidably coupling the rail to a height-adjustable base with a fastener. In some embodiments, a two-configuration, track-mounted, rectangular base is designed with a rectangular base having a pair of short-sided legs, a pair of long-sided legs, and a fastener for engaging outer surfaces of a track.