PV Module Mounting Clip With Integrated Grounding and Wind Resistance
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Solution Overview
Problem
Existing photovoltaic (PV) system mounting and grounding systems require multiple small fasteners, leading to high part counts, slow installation times, and increased costs, and often lack compatibility with different roof types or PV module designs, including those with grooved or flat surfaces, and fail to provide a reliable electrical ground bond.
Innovation Solution
A mounting apparatus comprising supports with upper and lower surfaces, tabs, and openings, along with a clip featuring an arm and notch, which resists wind and seismic forces while creating a grounding electrical bond between the PV module, support, and clip, allowing for efficient installation by arranging supports in rows and columns and connecting them to the PV module using lever clips that engage the module's frame.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If multiple small fasteners are used for mounting PV modules, then the connection strength is improved, but the installation time increases and part count increases
Solution Approach 1:
The patent combines multiple fastening functions into a single integrated mounting bracket assembly. The bracket incorporates multiple attachment points and fastening mechanisms that can secure PV modules using fewer individual fasteners, thereby reducing installation time while maintaining connection strength through the distributed fastening points integrated into the single bracket structure.
Solution Approach 2:
The mounting system is divided into modular components including separate brackets, fasteners, and support structures. This segmentation allows for pre-assembly and standardized installation procedures, reducing on-site installation time while maintaining the required connection strength through properly engineered modular interfaces.
2Reliability
If specialized flanges or tools are required for installation, then the mounting reliability is improved, but the ease of operation deteriorates and device complexity increases
Solution Approach 1:
The mounting bracket is designed with universal features that can accommodate different PV module types and roof structures without requiring specialized tools or flanges. The bracket incorporates standardized attachment mechanisms that work with common fastener types, making the system easier to install while maintaining reliability through proven mounting interfaces.
Solution Approach 2:
The mounting system incorporates self-aligning features and intuitive installation mechanisms that allow installers to properly mount PV modules without requiring specialized training or tools. The bracket design includes built-in alignment guides and self-adjusting components that ensure reliable mounting through proper installation procedures rather than specialized equipment.
3Reliability
If the mounting system is designed for specific roof types, then the mounting reliability is improved, but the adaptability deteriorates
Solution Approach 1:
The mounting bracket is designed as a universal system that can be adapted to different roof types including flat roofs, sloped roofs, and various structural configurations. The bracket incorporates adjustable mounting configurations and multiple attachment point options that maintain reliable mounting across different roof types without requiring roof-specific specialized components.
4Reliability
If a high part count is used in the mounting system, then the connection reliability is improved, but the device complexity increases and costs increase
Solution Approach 1:
The patent integrates multiple fastening and support functions into consolidated mounting bracket assemblies, reducing the total number of separate parts required. The integrated design maintains connection reliability by incorporating multiple fastening points and support features within each bracket, thereby reducing part count and simplifying the overall system while preserving mounting reliability.
Data Source
AI summary
An apparatus for mounting a photovoltaic (PV) module on a surface, including a support with an upper surface, a lower surface, tabs, one or more openings, and a clip comprising an arm and a notch, where the apparatus resists wind forces and seismic forces and creates a grounding electrical bond between the PV module, support, and clip. The invention further includes a method for installing PV modules on a surface that includes arranging supports in rows along an X axis and in columns along a Y axis on a surface such that in each row the distance between two neighboring supports does not exceed the length of the longest side of a PV module and in each column the distance between two neighboring supports does not exceed the length of the shortest side of a PV module.