Flexible PV Mounting Bracket With Integral Grounding
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Solution Overview
Problem
Current solar mounting systems are heavy, complex, and costly due to the need to support heavy photovoltaic modules and tracking equipment, requiring significant materials and skilled labor for installation and quality control, and are not adaptable to standard, custom, or unframed modules.
Innovation Solution
A flexible mounting bracket assembly with a torsion beam and integral grounding device that uses a single bolt for secure connection, featuring a flexible body with a beam insertion aperture, clamps, and a break-away clamping nut for efficient material use and easier installation, capable of securing and grounding photovoltaic modules with varying frame types.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional mounting systems use heavy components to support PV modules and withstand natural forces, then structural strength and stability are improved, but system weight and material usage increase significantly
Solution Approach 1:
The mounting bracket uses varying thickness profiles (e.g., 1/8" at certain locations, 3/16" at others) to provide structural strength only where needed rather than uniform thickness throughout, reducing overall material usage and weight while maintaining necessary support capabilities
Solution Approach 2:
The mounting system is divided into separate functional components including the bracket body, clamps, grounding devices, and torque-indicating features, allowing each segment to be optimized independently for its specific function rather than requiring a single heavy component to handle all requirements
2Reliability
If traditional mounting systems use complex assemblies with multiple components, then reliability and adaptability are improved, but device complexity and installation time increase
Solution Approach 1:
Multiple functions are merged into the single bracket body including structural support, grounding capability, torque indication, and module securing mechanisms, eliminating the need for separate components for each function and simplifying the overall assembly
Solution Approach 2:
The bracket design with varying thickness profiles and configurable clamps can accommodate different PV module types (standard framed, custom framed, and unframed) and provides multiple functions (mounting, grounding, torque indication) within a single component, reducing the number of different bracket types needed
3Reliability
If traditional mounting systems require multiple fasteners and complex assembly steps, then secure connection is improved, but installation time and labor costs increase
Solution Approach 1:
The bracket is pre-configured with integrated grounding devices, torque-indicating features, and positioning elements during manufacturing, so that during installation the worker only needs to attach the module and tighten a single clamp rather than assembling multiple separate components and fasteners
4Manufacturing precision
If traditional mounting systems are designed for specific PV module types, then mounting precision is improved, but adaptability to different module types decreases
Solution Approach 1:
The bracket's varying thickness profile and configurable clamp system can adapt to different PV module types (standard framed, custom framed, and unframed) while maintaining precise mounting through the integrated grounding devices and torque-indicating features, eliminating the need for different bracket designs for different module types
Data Source
AI summary
A mounting bracket assembly comprises a flexible body including at least one top member and a flexible angled bottom member connected to the top member. The flexible body defines a beam insertion aperture between the top member and the bottom member. The mounting bracket assembly further comprises at least one clamp attached to the top member. The mounting bracket assembly may further comprise a threaded rod running through the at least one top member and a clamping nut securing the threaded rod to the top member such that rotating the clamping nut compresses the top member and grounds an electricity generating device such as a photovoltaic module. The mounting bracket assembly may further comprise an integral grounding device disposed adjacent the top member to electrically ground the electricity generating device.