Modular Photovoltaic Mounting Rails With Resilient Brackets
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Solution Overview
Problem
Existing photovoltaic assemblies are non-integrated, heavy, require significant installation efforts, and are prone to environmental damage, corrosion, noise, and waterproofing issues, with complex mounting processes that are time-consuming and require precision.
Innovation Solution
A modular photovoltaic assembly with simplified design and mounting brackets that engage with rails, allowing for easy customization and installation on building exteriors, reducing labor and costs, and featuring resilient arms and spacers for secure mounting without additional components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional separate support structures are used for photovoltaic modules, then the photovoltaic system can be installed on building exteriors, but the assembly becomes heavy and requires significant installation efforts
Solution Approach 1:
The patent combines the support structure and photovoltaic module into a single integrated assembly. The mounting brackets are directly attached to the photovoltaic module backsheet, eliminating the need for separate support structures. This integration reduces the overall weight and simplifies installation while maintaining structural stability.
Solution Approach 2:
The photovoltaic assembly is divided into modular components: photovoltaic modules, mounting brackets, and mounting rails. Each module is a self-contained unit that can be independently handled and installed, reducing the weight of individual components being moved and installed separately rather than as one large heavy assembly.
2Reliability
If traditional mounting methods with multiple components are used, then secure attachment is achieved, but installation time and labor costs increase
Solution Approach 1:
The mounting bracket integrates multiple functions into a single component: it provides attachment to the photovoltaic module, connection to the mounting rail, and structural support. This consolidation reduces the number of parts that need to be handled and assembled, significantly reducing installation time while maintaining secure attachment through the resilient arm mechanism and slot engagement.
3Reliability
If precision placement of mounting components is required, then secure mounting is achieved, but the installation process becomes complex and time-consuming
Solution Approach 1:
The mounting bracket uses a resilient arm that can flex and adapt to slight variations in positioning. The resilient nature of the arm allows it to compensate for minor misalignments between the mounting rail slot and bracket hole, reducing the precision requirements for installation while still achieving secure mounting through the elastic engagement mechanism.
4Power
If traditional photovoltaic assemblies are used, then electricity generation is achieved, but vulnerability to environmental damage and corrosion occurs
Solution Approach 1:
The mounting bracket is constructed from corrosion-resistant materials such as anodized aluminum or stainless steel. The photovoltaic module itself is a composite structure with tempered glass, encapsulant, and backsheet that provides protection against environmental damage. This use of composite and corrosion-resistant materials enhances the overall environmental resistance of the photovoltaic assembly while maintaining electricity generation capability.
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
Facilitates quick and easy installation of photovoltaic panels on building exteriors, minimizing precision requirements and preventing environmental damage, while ensuring secure and weather-resistant integration with building materials.
Implementation Method 1
the first lateral end comprising a resilient arm adapted to be fittingly received in a slotted recess of the distal end of each mounting rail, the second lateral end comprising an upper resilient member and a lower resilient member spaced a distance apart on the z-axis
Data Source
AI summary
Provided herein is a modular photovoltaic assembly configured for installation on an exterior of a building that includes a photovoltaic panel, first and second mounting rails, and first and second mounting brackets configured to fittingly engage with each of the first and second mounting rails, where each mounting bracket has a length on the longitudinal axis between opposing first and second lateral ends, the first lateral end having a resilient arm adapted to be fittingly received in a slotted recess of a distal end of each mounting rail, the second lateral end having an upper resilient member and a lower resilient member spaced a distance apart on the z-axis, and the upper and lower resilient members are adapted to fittingly secure therebetween a portion of one of the photovoltaic panel, another adjacent photovoltaic panel, a building or fitting panel, and a roof tile.