Modular Strap Mounting for Stable Low-Cost Solar Panels
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Solution Overview
Problem
Existing solar panel mounting systems are heavy, expensive, and time-consuming to install, necessitating a more cost-effective and efficient solution for fabrication and installation.
Innovation Solution
A modular strap mounting system comprising a strap assembly with predrilled holes for easy assembly, supported by brackets with different heights and attachment methods such as nails, spikes, adhesive, or welding, allowing for flexible attachment to various surfaces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional mounting systems are used, then stability and proper orientation are achieved, but fabrication cost and installation time increase
Solution Approach 1:
The mounting system is divided into separate components: a mounting member with attachment means for the substrate surface, and a solar panel support structure. These segments can be manufactured independently and assembled on-site, reducing fabrication complexity and cost while maintaining stability.
Solution Approach 2:
The mounting member is designed with universal attachment means that can be adapted to different substrate surfaces (roofs, walls, ground) through various attachment methods (ballast, flush mounting, standing seams, adjustable mounts). This multi-functionality reduces the need for multiple specialized components, lowering overall fabrication cost.
2Reliability
If traditional mounting systems are used, then stability and proper orientation are achieved, but installation time increases
Solution Approach 1:
The mounting member and support structure are designed with pre-configured attachment mechanisms and geometric relationships that enable quick assembly. The support structure is preliminarily shaped to receive the solar panel, and the mounting member includes pre-designed attachment means, allowing rapid installation without complex field fabrication.
Solution Approach 2:
The system incorporates adjustable mounts that allow for dynamic adaptation during installation to different surface conditions and panel orientations. This adjustability speeds up installation by eliminating the need for custom fabrication for each specific installation scenario.
3Reliability
If heavy mounting systems are used, then stability is improved, but weight and cost increase
Solution Approach 1:
The mounting member and support structure are designed with thin-walled but structurally efficient geometries that provide the necessary stability and strength while minimizing material usage and overall weight. The segmented design allows each component to be optimized for its specific function with minimal material.
4Reliability
If complex mounting systems are used, then proper orientation and stability are achieved, but device complexity and installation time increase
Solution Approach 1:
The mounting system is segmented into functional components with clear interfaces: a mounting member for substrate attachment, and a support structure for panel mounting. This segmentation simplifies each individual component's design and complexity while achieving proper orientation through the geometric relationship between segments.
Data Source
AI summary
A method and apparatus for mounting a solar collector panel by itself or supported within a frame, to a surface comprising: a strap assembly, a first attachment device attached to and between the panel or frame and the strap assembly; and a second attachment means for attaching the strap assembly to the surface. The strap assembly comprises a plurality of straps attached end to end. The first attachment device could be a bolt, a screw, adhesive, etc. Alternatively, there could be a support between the panel or frame and the strap assembly. The second attachment means may be: a nail, a spike, adhesive, bolting to a stud attached to the surface, welding, ballast, adhesive tape or combinations of these.