Lever-Lock PV Module Mounting for Low-Tool Roof Installation
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Solution Overview
Problem
The existing photovoltaic mounting systems for rooftops are costly and labor-intensive, requiring significant tool usage and often necessitate additional components like metal flashings that increase expenses and potential water ingress issues.
Innovation Solution
A self-locking photovoltaic mounting system utilizing a lever-lock mechanism that couples photovoltaic modules with manual torque, incorporating a planar base with adjustable channels and a torque lever for easy installation, along with optional flashings that minimize tool usage and prevent water ingress, while allowing for adjustable and secure module positioning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional photovoltaic mounting systems are used, then secure module attachment is achieved, but installation cost and labor intensity increase significantly
Solution Approach 1:
The mounting system incorporates a self-locking mechanism where the mounting bracket automatically secures the photovoltaic module through a cam-actuated locking feature. When the module is placed on the bracket, the locking feature engages with the module frame to provide secure attachment without requiring additional fasteners or complex installation tools, thereby reducing labor costs while maintaining reliable attachment
Solution Approach 2:
The mounting bracket integrates multiple functions into a single component: it provides structural support, module attachment, and self-locking capability all in one device. This consolidation eliminates the need for separate flashings, fasteners, and adjustment mechanisms that are typically required in conventional systems, reducing both material costs and installation complexity
2Object-affected harmful factors
If conventional mounting systems with metal flashings are used, then water protection is provided, but material cost and potential water ingress issues increase
Solution Approach 1:
The mounting bracket uses a simplified flashing design made from cost-effective materials that provides adequate water protection for the installation lifecycle. The flashing is integrated directly into the bracket structure rather than being a separate metal component, reducing material costs while maintaining sufficient protective function
Solution Approach 2:
The mounting bracket acts as an intermediary element between the roof structure and the photovoltaic module, providing a sealed interface that prevents water ingress. The integrated flashing design creates a continuous water barrier without requiring additional metal flashings that could potentially corrode or fail over time
3Stability of the object's composition
If conventional mounting systems are used, then module positioning is secured, but installation complexity and tool usage increase
Solution Approach 1:
The mounting bracket incorporates adjustable channels that allow the bracket to be positioned at various locations along the rafter. The bracket can be adjusted during installation to accommodate different module positions and roof configurations, then locked into place. This adjustability simplifies installation by eliminating the need for precise pre-drilling and complex alignment procedures while maintaining stable module positioning
Data Source
AI summary
A photovoltaic module mounting assembly including a photovoltaic module lever lock and base portion for attaching photovoltaic modules to a roof surface. The base portion includes one or more parallel channels that provide access to one or more corresponding recesses formed in a top surface of the base portion. The lever lock includes a lobe at one end, a torque lever at the other and supports a photovoltaic module connector. The lobe is dimensioned to fit into the channel at a first orientation, and upon rotation of approximately 90 degrees, to fit into the recess at a second orientation. The module connector may support two or more photovoltaic modules.