Monolithic PV Mounting Bracket With Ballast Tray and Bent Support Legs
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Solution Overview
Problem
The solar industry requires more efficient and simplified structures for mounting photovoltaic modules that reduce complexity and installation time while minimizing costs and shipping costs, and existing solutions often involve multiple parts and complex configurations.
Innovation Solution
A monolithic, single-piece mounting bracket system is developed, featuring a ballast tray with support legs bent at an acute angle from the tray, manufactured by stamping and bending sheet metal, which reduces the number of parts and allows for stackable, symmetrical designs that can be easily assembled and securely hold ballast blocks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple separate parts are used to mount photovoltaic modules, then the mounting structure can be flexible and adaptable, but the device complexity increases and installation time increases
Solution Approach 1:
The patent combines multiple separate mounting components (ballast tray, support legs, and mounting flanges) into a single monolithic bracket made from one piece of sheet metal. This integration eliminates the need for separate parts while maintaining the functional adaptability of the mounting structure for photovoltaic modules.
Solution Approach 2:
The monolithic bracket is designed to perform multiple functions simultaneously: it provides ballast retention, structural support through bent legs, and module mounting capabilities. This multi-functionality reduces the number of separate components needed while maintaining versatility in mounting configurations.
2Adaptability or versatility
If multiple separate parts are used for mounting, then the structure can be adjusted and adapted, but the installation time increases
Solution Approach 1:
By integrating all mounting functions into a single pre-assembled monolithic bracket, the patent eliminates the time required to assemble multiple separate parts on-site. The bracket arrives ready-to-install with all components permanently integrated, significantly reducing installation time while preserving adaptability through design variations.
3Adaptability or versatility
If multiple separate parts are used, then the mounting structure can be modular, but the manufacturing costs and shipping costs increase
Solution Approach 1:
The patent reduces manufacturing complexity by creating a single-piece bracket from sheet metal through stamping and bending operations, eliminating the need to manufacture, inventory, and ship multiple separate components. This consolidation reduces overall manufacturing costs and shipping expenses while maintaining the adaptability needed for different mounting configurations.
Data Source
AI summary
An integral, monolithic mounting bracket supports a corner of a photovoltaic module. The bracket includes a ballast tray for holding one or more ballast blocks, and includes a plurality of monolithic support legs that are disposed at acute angles from a plane of the ballast tray and that are integral with the ballast tray. The bracket can be manufactured by stamping at least two identical sections of metal from the sheet and then bending-up each section on its remaining uncut fourth side into a near-vertical position, so that each bent-up section forms a monolithic support leg.