L-Bracket and Flashing Assembly for Water-Tight Solar Rack Mounting
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Solution Overview
Problem
Existing solar-panel rack mounting systems using L-brackets and flashing assemblies with rubberized sub-assemblies are prone to water-tight seal degradation due to sunlight and heat, leading to potential water penetration into the roof interior.
Innovation Solution
A flashing and L-bracket assembly where the L-bracket is inserted below a raised portion of the flashing sub-assembly, eliminating the need for a rubberized sub-assembly and enhancing water-tightness by directing water away from the lag bolt, optionally using an O-ring for additional sealing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a rubberized sub-assembly is used to seal the lag bolt, then water-tight sealing is achieved, but the seal degrades over time due to sunlight and heat
Solution Approach 1:
The patent removes the rubberized sub-assembly from the mounting system entirely. Instead of relying on a rubber seal that degrades, the design uses the upraised portion of the flashing to create a physical barrier and drainage path that eliminates the need for rubber components, thereby solving the degradation problem while maintaining water-tight sealing.
Solution Approach 2:
The upraised portion of the flashing acts as an intermediary element between the lag bolt and the external environment. It creates a protected cavity that shields the lag bolt from direct water exposure and provides a drainage path, serving as a mediator that prevents water infiltration without requiring degradable rubber materials.
2Ease of operation
If the L-bracket sits atop the flashing, then installation is simple, but water can penetrate around the lag bolt
Solution Approach 1:
The patent introduces a vertical dimension to the flashing by creating an upraised portion that extends upward from the flat flashing surface. This dimensional change creates a three-dimensional structure that forms a protective cavity around the lag bolt, preventing water from reaching the bolt while maintaining the simplicity of the installation process.
3Strength
If the lag bolt passes through the L-bracket and flashing, then secure mounting is achieved, but water-tight sealing becomes complex
Solution Approach 1:
The patent eliminates the complex sealing components (rubberized sub-assembly, gaskets, washers) by using the upraised flashing structure itself as the sealing mechanism. The vertical wall of the upraised portion creates a physical barrier that simplifies the sealing approach while maintaining secure mounting through the lag bolt.
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
This design improves water-tightness and simplifies installation by reducing component count and avoiding rubberized sub-assembly degradation, ensuring a more reliable and leak-resistant seal.
Implementation Method 1
Because the upraised portion of the flashing sub-assembly is higher than the surrounding sheet material, it creates a flow path away from the lag bolt and onto the lower portion of the flashing assembly
Data Source
AI summary
The invention herein disclosed and claimed is an L-bracket and flashing assembly used to mount a rack for supporting a solar-panel array. It uses fewer sub-assemblies and is simpler and faster to install than prior art L-bracket and flashing assemblies.