Hinged Solar Panel Mounting for Corrugated and Trapezoidal Roofs
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Solution Overview
Problem
Existing solar panel racking systems are limited in their ability to securely attach solar panels to various metal roof profiles, including corrugated, trapezoidal, and flat roofs, due to the lack of adaptable and adjustable mounting solutions.
Innovation Solution
A hinged and optionally adjustable mounting device with hinge bases and arcuate-shaped sleeves is developed, allowing for secure attachment to different metal roof profiles by pivoting and adjusting to accommodate various profiles, using self-drilling screws and a hinge platform assembly that can be adjusted in width.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a fixed mounting device is used, then the structure is simple, but it cannot accommodate various metal roof profiles
Solution Approach 1:
The mounting device incorporates a hinge mechanism that allows the mounting arm to pivot relative to the base, transforming a static structure into a dynamic one. This enables the mounting arm to adjust its angle and position to accommodate different roof profiles including corrugated, ribbed, and flat roofs, while maintaining structural simplicity through controlled movement rather than complex adjustable components
Solution Approach 2:
The mounting device is designed with a universal base that can attach to various roof types through a single installation method, while the hinged arm provides multi-position capability. This single device structure serves multiple functions by accommodating corrugated roofs, ribbed roofs, and flat roofs without requiring profile-specific mounting hardware, thereby reducing overall system complexity
2Reliability
If multiple racking systems are used for different roof profiles, then each system is optimized for its specific profile, but the overall system complexity and installation time increase
Solution Approach 1:
The mounting device provides reliable attachment to corrugated, ribbed, and flat roofs through a single universal design. The base structure with its specific geometry and the hinged arm combination creates one system that can securely mount to multiple roof profiles, eliminating the need for installers to select different racking systems for different roof types and significantly reducing installation time
3Reliability
If multiple racking systems are used for different roof profiles, then each system is optimized for its specific profile, but the inventory requirements and cost increase
Solution Approach 1:
The mounting device consolidates multiple specialized racking systems into a single universal product. By designing a base and hinged arm combination that can securely attach to corrugated, ribbed, and flat roofs, the invention eliminates the need for distributors and installers to maintain inventory of multiple different racking systems, thereby reducing overall quantity of materials required and associated costs
Data Source
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AI summary
This disclosure discusses devices and systems for attaching solar panels to metal roofs. A mounting device has two or more hinge bases that can pivot at various angles about a hinge platform assembly. The hinge platform assembly is optionally widthwise adjustable. The above-mentioned adjustments allow the mounting device to secure solar panels to various types of metal roofs such as flat, corrugated, and trapezoidal. The hinge platform assembly interfaces with various components of the solar panel racking system. The hinge platform assembly includes hinge sleeves that pass into slots within the hinge bases and surround hinge pins that project upward from the hinge bases. This allows the hinge bases to captively rotate about the hinge platform assembly.