PV Module Flashing-Based Mounting Assembly to Reduce Installation Time
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Solution Overview
Problem
Existing methods for securing photovoltaic (PV) modules to roofs are inefficient, requiring extensive attic work, large holes in roofing materials, and specialized mounting structures, which complicates installation, increases costs, and may not ensure adequate waterproofing.
Innovation Solution
A PV module mounting and support assembly that uses flashing between the module and the roof deck, with deck-penetrating fasteners and mounting hardware that allows for secure attachment without the need for conventional rails or attic access, enabling low-profile installation and potential integration of grounding functions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional rack systems with vertical stanchions and lateral rails are used, then PV modules can be mounted on roofs with various joist spacings, but the device complexity increases and installation time increases
Solution Approach 1:
The patent removes the intermediate rails and stanchions from the mounting system, extracting the unnecessary components that add complexity. The PV modules are mounted directly to the roof deck using simplified flashing and fastener assemblies, eliminating the multi-component rack structure while maintaining adaptability to different roof configurations
Solution Approach 2:
The patent combines multiple functions into a single integrated flashing assembly that serves as both the mounting base and waterproofing element. The flashing incorporates the mounting hardware and sealing components directly, merging what were previously separate elements (flashing, fasteners, seals) into one unified component that reduces overall system complexity
2Reliability
If blocking members are installed between rafters in the attic for mounting PV modules, then secure attachment is achieved, but installation time increases significantly due to extensive attic work
Solution Approach 1:
The flashing assemblies are pre-assembled with all mounting components attached before reaching the roof. The fasteners are pre-positioned and sealed within the flashing structure, so that during installation, workers simply need to position and secure the pre-prepared flashing units to the deck, eliminating time-consuming on-site assembly and attic work
Solution Approach 2:
The flashing acts as an intermediary component that provides a pre-fabricated mounting interface between the PV module and the roof deck. This intermediary element contains all necessary attachment and sealing features, eliminating the need for workers to perform complex blocking installation and waterproofing tasks in the attic
3Reliability
If vertical stanchions and lateral rails are used to mount PV modules, then modules can be secured to the roof, but the profile height increases and aesthetics are reduced
Solution Approach 1:
The patent removes the height-contributing elements (stanchions and rails) from the mounting system, extracting only the essential function of securing the module to the roof. The flashing-based mounting approach allows the PV module to sit much closer to the roof surface, dramatically reducing the visible profile height while maintaining secure attachment
Data Source
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AI summary
In some examples a PV module mounting and support assembly includes a base mountable to the deck, a deck-penetrating fastener for securing the base to the deck, and PV module mounting hardware. The PV module mounting hardware is used to secure an edge of a PV module on a PV module-support surface of the base with the edge of the PV module spaced apart from the deck. Flashing may be used between the lower surface and the deck. In some examples an internal PV mounting and support assembly is used to engage an internal lip of the PV module frame. In some examples a PV module mounting assembly, for use on a deck on which shingles are mounted, comprises flashing, a base mountable on the flashing, a deck- penetrating fastener engageable with the base and securable to the deck so to secure the flashing and the base to the shingled support surface, and PV module mounting hardware securable to the base.