PV Module Mounting Clip and Flashing for Tile Roof Alignment
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing flashing devices for solar panels are inadequate for mounting on Spanish tile or S tiled roofs, lack adjustability, and do not provide sufficient pressure for a watertight seal, nor do they optimize material usage or account for misalignment during installation.
Innovation Solution
A mounting apparatus comprising a base portion, a stud portion, and a coupling portion with a spring mechanism that creates a grounding bond, allowing for adjustable installation and improved aesthetics, including a replacement roof tile design with a support structure and flashing that mimics the shape of adjacent tiles to facilitate easier installation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional flashings are used for mounting solar panels, then installation is possible on shingled or metal roofs, but the flashings cannot be used on Spanish tile or S tiled roofs without cutting or modifying tiles
Solution Approach 1:
The flashing device is designed with a universal mounting structure that can accommodate multiple roof types including Spanish tile, S tile, shingled, and metal roofs through a single device design, eliminating the need for different flashing types for different roof styles
Solution Approach 2:
The flashing device is divided into separate functional components including a mounting portion that attaches to the roof structure and a sealing portion that interfaces with tiles, allowing the same mounting portion to work with various roof types while the sealing portion adapts to different tile configurations
2Reliability
If conventional flashings are used, then mounting is possible, but the flashings do not provide adequate pressure on the seal around the lag screw
Solution Approach 1:
The flashing device incorporates a spring mechanism that applies continuous variable pressure to the seal around the lag screw, maintaining optimal sealing force under different loading conditions and preventing water infiltration
Solution Approach 2:
The static flashing design is replaced with a dynamic spring-loaded sealing mechanism that automatically adjusts pressure in response to thermal expansion, contraction, and structural movement, ensuring consistent seal integrity
3Adaptability or versatility
If conventional flashings are used, then mounting is possible, but the flashings do not allow for a separately positionable bracket that enables adjustability relative to the lag screw after installation
Solution Approach 1:
The bracket system incorporates movable and adjustable components that allow repositioning relative to the lag screw after installation, enabling adaptation to misaligned holes or varying module positions without requiring complete disassembly
Solution Approach 2:
The bracket is separated into multiple independently positionable segments that can be adjusted and locked at different locations, providing flexibility in positioning while maintaining structural integrity
4Adaptability or versatility
If conventional flashings are used, then mounting is possible, but the flashings do not comprise a support portion with multiple holes or slots for connecting brackets and/or other devices in various positions
Solution Approach 1:
The support portion of the flashing device includes multiple pre-drilled holes and slots arranged in various patterns that accommodate different bracket positions and orientations, allowing a single flashing design to serve multiple mounting configurations
5Reliability
If conventional flashings are used, then mounting is possible, but the flashings are costly and do not optimize materials usage
Solution Approach 1:
The flashing device design minimizes material waste by optimizing the shape and dimensions to use only the necessary amount of material for effective sealing and mounting, eliminating excess material that would be discarded during installation or manufacturing
6Reliability
If conventional flashings are used, then mounting is possible, but the flashings create seals from brittle materials that have higher failure rates than resilient materials
Solution Approach 1:
The seal material is changed from brittle materials to resilient materials with improved elastic properties, allowing the seal to accommodate movement and stress without cracking or failing
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution enables easier and faster installation of PV arrays on tile roofs, improves electrical grounding, and enhances the aesthetic appeal while reducing material waste and installation time.
Implementation Method 1
The coupling portion comprises a male portion that may act as a spring under load
Implementation Method 2
The apparatus further includes a key portion that can compress to allow for tolerances
Implementation Method 3
causing spring expansion of the groove
Implementation Method 4
a clip portion that may penetrate the PV module frame to create a grounding bond
Data Source
AI summary
The invention includes an apparatus for mounting a photovoltaic (PV) module on a structure where the apparatus includes a base portion, a stud portion, and a coupling portion. The coupling portion includes a male portion that acts as a spring under load and a clip portion that penetrates the PV module frame to create a grounding bond. The apparatus includes a lower jaw, shaped to pry open a groove, and a key portion that can compress to allow for tolerances. The invention further includes a clip with one or more tabs and one or more teeth. The invention further includes a replacement roof tile which includes a support structure with a horizontal flange, a vertical component, a horizontal component, a flashing with an upper surface and a lower surface, and a tile-shaped metal surface having a curvilinear shape that reflects the shapes of adjacent tiles.