Mounting bracket assemblies and methods
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Solution Overview
Problem
Current solar mounting systems are heavy, complex, and costly due to the need to support heavy PV modules and withstand natural forces, requiring significant materials and skilled labor for installation, and often lack versatility to accommodate standard, custom, and unframed modules, as well as being inadequate in harsh environments with high loads and corrosive conditions.
Innovation Solution
A mounting bracket assembly with a flexible body and integral grounding device that securely connects PV modules to a torsion beam using a single bolt, featuring a clamping nut that compresses a grounding block for electrical grounding and a break-away component indicating proper torque, allowing for efficient material use, easier installation, and adaptability to various module types and environments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional mounting systems use heavy components to support PV modules and withstand natural forces, then structural strength and reliability are improved, but system weight and material usage increase significantly
Solution Approach 1:
The patent employs a torsion beam with a thin-walled hollow circular cross-section that provides high strength-to-weight ratio. The hollow structure acts as a flexible shell that resists bending and torsional forces while minimizing material usage, allowing the system to withstand natural forces without requiring heavy solid components
Solution Approach 2:
The mounting system combines aluminum extrusions with stainless steel fasteners and grounding components. The aluminum torsion beam provides lightweight structural support, while stainless steel components provide corrosion resistance and grounding capability, creating a composite system that optimizes both strength and weight
2Reliability
If traditional mounting systems use multiple components and complex assemblies, then structural reliability is improved, but device complexity and installation time increase
Solution Approach 1:
The patent integrates multiple functions into unified components. The torsion beam combines structural support, rotation capability, and grounding functions. The mounting bracket assembly integrates clamping, positioning, and electrical grounding capabilities. The single fastener system combines securing and torque indication functions, reducing the number of separate components while maintaining reliability
Solution Approach 2:
The mounting system is designed to accommodate multiple PV module types (standard framed, custom framed, and unframed modules) using the same basic bracket assembly. The adjustable clamp positions and flexible mounting configurations allow a single design to serve multiple applications, reducing complexity while maintaining versatility and reliability
3Manufacturing precision
If traditional mounting systems are designed for specific PV module types, then mounting precision is improved, but adaptability to different module types decreases
Solution Approach 1:
The mounting bracket assembly incorporates adjustable and movable elements that can be configured for different module types. The clamp positions can be adjusted along the bracket, and the bracket itself can be positioned at various locations on the torsion beam. This dynamic adjustability maintains precise mounting for each specific module type while providing versatility across different configurations
Solution Approach 2:
The mounting system uses universal bracket designs that can accommodate standard framed modules, custom framed modules, and unframed modules through different clamping configurations. The same basic bracket assembly serves multiple module types by adjusting clamp positions and securing methods, maintaining mounting precision for each type while achieving broad adaptability
4Reliability
If traditional mounting systems use multiple fasteners and components, then connection reliability is improved, but installation time and labor cost increase
Solution Approach 1:
The mounting bracket assembly is pre-configured with integrated grounding devices and pre-positioned clamp elements during manufacturing. The grounding block is pre-attached to the bracket, and clamp positions are predetermined. This preliminary preparation reduces on-site assembly steps and installation time while maintaining connection reliability through factory-quality connections
Solution Approach 2:
The patent combines multiple connection functions into a single fastener system. One fastener simultaneously secures the bracket to the torsion beam, positions the mounting assembly, and engages the grounding connection. This merging of functions reduces the number of installation steps and fasteners required while maintaining connection reliability through integrated design
Data Source
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AI summary
A mounting bracket assembly is provided in which a mounting bracket includes a first attachable bracket piece and a second attachable bracket piece, a first fastener, a second fastener, and a third fastener. Each attachable bracket piece has a top member and a bottom member connected to the top member at an angle. The first clamp is attached to the top member of the first attachable bracket piece by the first fastener. The second clamp is attached to the top member of the second attachable bracket piece by a second fastener. The third fastener secures the bottom member of the first attachable bracket piece to the bottom member of the second attachable bracket piece. The mounting bracket defines a beam insertion aperture between the top members and the bottom members. The mounting bracket assembly may include a grounding device located adjacent the top member of the first or second attachable bracket piece.