L-Foot Bracket with Angled Fasteners to Reduce Power Tool Interference
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Solution Overview
Problem
Solar panel racking systems often interfere with power tools during the installation of roof mounting brackets, particularly due to the large number of brackets required for residential and commercial arrays, which can lead to clearance issues and reduced holding strength.
Innovation Solution
The L-foot bracket design allows for angled installation of threaded roof fasteners, providing superior holding strength and reducing interference with power tools, while its raised stiffeners and optional gasket enhance structural rigidity and waterproofing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If threaded roof fasteners are installed perpendicular to the roof deck, then installation is simpler, but power tool interference with solar panel racking system occurs
Solution Approach 1:
The bracket is designed with an asymmetric configuration where the base extends beyond the vertical centerline of the riser, creating offset apertures that angle fasteners inward at 30-60 degrees. This asymmetric geometry allows power tools to approach from the outer edge without interfering with the solar panel racking system, resolving the contradiction between installation simplicity and tool interference.
Solution Approach 2:
Instead of installing fasteners in a single perpendicular direction, the invention changes the dimensional approach by angling fasteners inward through the offset base design. This dimensional change in fastener trajectory allows the power tool to operate from the outer perimeter while the angled fastener path avoids interference with the racking system components.
2Strength
If more roof mounting brackets are used per solar panel, then structural strength is improved, but power tool clearance issues worsen
Solution Approach 1:
The asymmetric offset base design allows multiple fasteners to be installed at angles without requiring additional brackets. The inward-angling fasteners distributed across the offset base provide enhanced holding strength while maintaining clear clearance for power tools, eliminating the need to increase bracket quantity.
Solution Approach 2:
The invention changes the fastener installation parameters by angling them inward at 30-60 degrees rather than perpendicular installation. This parameter change in fastener trajectory, combined with the offset base geometry, provides superior holding strength through increased engagement with the roof deck while maintaining adequate power tool clearance.
3Object-affected harmful factors
If angled fastener installation is used, then power tool interference is reduced, but installation complexity increases
Solution Approach 1:
The bracket is pre-designed and manufactured with the asymmetric offset base and pre-positioned apertures that dictate the angled fastener path. This preliminary action of pre-configuring the bracket geometry eliminates the need for complex field calculations or adjustments, making the angled installation as straightforward as perpendicular installation despite the different trajectory.
Solution Approach 2:
The asymmetric offset base design with pre-positioned apertures provides built-in guidance for angled fastener installation. The geometry itself guides the installer through the angled path, reducing the perceived complexity despite the non-traditional installation angle, as the bracket design encapsulates the complexity rather than requiring complex installation procedures.
Data Source
AI summary
A bracket for attaching solar panels to a roof, in the form of an L-foot, as well as devices and assemblies that utilize the L-foot. The L-foot includes a base and a riser extending upward from the base. The base includes a pair of raised stiffeners each extending obliquely upward toward each other from opposites sides of the base and each extending lengthwise along the base. The base can receive threaded roof fasteners that extend perpendicularly through the raised stiffeners and obliquely through the base. Threaded roof fasteners positioned on opposite raised stiffeners can extend through the roof deck toward each other. The L-foot is compatible with rail-based and rail-less solar panel racking systems.