Modular Photovoltaic Mounting Assembly for Fast Weatherproof Installation
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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 structure, featuring first and second mounting rails and brackets with resilient arms and members, allowing for easy customization, quick installation, and integration with building exteriors 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 mounting functions into an integrated rail system that attaches directly to roof tiles or building panels. The mounting brackets integrate the rail attachment, panel securing, and structural support functions into a single component, eliminating the need for separate heavy support structures while maintaining installation reliability
Solution Approach 2:
The mounting brackets are designed with multi-functionality to perform multiple tasks: attaching to roof tiles or building panels, supporting the photovoltaic panels, providing adjustment mechanisms for positioning, and ensuring structural stability. This universal design reduces the need for additional specialized components, thereby reducing overall assembly weight
2Strength
If traditional mounting structures with multiple components are used, then the photovoltaic panels can be securely attached, but the installation process becomes time-consuming and complex
Solution Approach 1:
The mounting system is segmented into modular components: rails that attach to the roof structure, brackets that connect to the rails, and clamping mechanisms that secure the panels. This segmentation allows for pre-assembly and standardized installation procedures, reducing on-site complexity and installation time while maintaining secure attachment
Solution Approach 2:
The mounting brackets are designed with pre-configured attachment mechanisms and adjustment features that are prepared during manufacturing. The rails come pre-drilled with mounting holes and the brackets include pre-assembled clamping components, eliminating the need for complex field assembly and reducing installation time while ensuring secure mounting
3Power
If conventional photovoltaic assemblies are installed on building exteriors, then electricity generation is achieved, but vulnerability to wind damage and environmental factors increases
Solution Approach 1:
The mounting system employs local quality enhancements at critical stress points: reinforced attachment zones where rails connect to roof tiles, strengthened bracket joints at panel corners, and localized reinforcement at wind load exposure areas. This targeted reinforcement provides enhanced environmental resistance without requiring uniform thickening of all components
Solution Approach 2:
The design incorporates protective features beforehand: the integrated rail system includes built-in drainage channels to prevent water accumulation, the mounting brackets have corrosion-resistant coatings applied during manufacturing, and the structure includes flexible mounting elements that can accommodate thermal expansion and contraction, providing protection against environmental damage before exposure occurs
4Adaptability or versatility
If non-integrated photovoltaic systems are used, then photovoltaic modules can be installed on existing roofs, but waterproofing issues and leakages occur at attachment points
Solution Approach 1:
The mounting system introduces intermediary elements between the photovoltaic structure and the roof: integrated flashing components that seal around roof penetrations, gaskets and sealants built into the bracket design, and waterproof membrane integrations that direct water flow away from attachment points. These intermediaries maintain roof waterproofing while enabling installation on existing roofs
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
The assembly reduces labor efforts and costs, enhances installation speed and ease, and provides improved durability and weather resistance, while minimizing environmental vulnerabilities.
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, and the upper and lower resilient members adapted to fittingly secure therebetween a portion of one of the photovoltaic panel
Data Source
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AI summary
Provided herein is a modular photovoltaic assembly configured for installation on an exterior of a building that includes a photovoltaic panel (1), first and second mounting rails (2a, 2b), and first and second mounting brackets (5a, 5b) configured to fittingly engage with each of the first and second mounting rails, where each mounting bracket has a length on the longitudinal axis (y) between opposing first and second lateral ends (50a, 50b), the first lateral end having a resilient arm (51) 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 (52) and a lower resilient member (53) 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 (1), another adjacent photovoltaic panel (10), a building or fitting panel, and a roof tile.