Standing-Seam PV Mounting Plate for Non-Penetrating Alignment and Grounding

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Solution Overview

Problem

Existing methods for installing photovoltaic modules on standing seam metal panel building surfaces often require puncturing the surface, leading to costly repairs, leakage, and corrosion issues, and lack efficient alignment and grounding solutions.

Innovation Solution

A mounting assembly comprising a mounting device, a mounting plate, a clamping member, and a threaded clamp fastener that secures to the standing seam without penetrating it, featuring positional registrants for alignment and grounding projections for electrical connection, allowing for secure and efficient installation of photovoltaic modules.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If puncturing methods are used to install photovoltaic modules on standing seam metal panels, then installation is simpler, but the building surface suffers damage, leakage, and corrosion issues

Engineering Contradiction:

Improveinstallation simplicityVSAvoidbuilding surface damage, leakage, and corrosion

Core Design Contradiction:

Ease of operationVSObject-affected harmful factors

Solution Approach 1:

The mounting device acts as an intermediary component that attaches to the standing seam panels without puncturing them. It uses a clamping mechanism with engagement members that grip the panel edges and a tensioning member that applies force to secure the photovoltaic module, thereby avoiding direct penetration of the building surface while achieving firm installation

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The invention replaces the traditional mechanical puncturing system with a tension-based clamping system. Instead of using bolts or screws that penetrate the panels, the system uses a tensioning member (such as a cable or rod) that applies mechanical tension to the engagement members, which then clamp onto the panel edges to hold the module in place

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Reliability

If standing seam panels are used for building surfaces, then aesthetic and durability are improved, but installation cost increases due to expensive panels and potential repair needs

Engineering Contradiction:

Improvebuilding surface durability and aestheticsVSAvoidinstallation cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The invention extracts the mounting function from the building surface itself, creating a separate, dedicated mounting system that attaches to the standing seam panels without damaging them. This separation allows the expensive panels to maintain their integrity while the mounting system bears the installation stresses, preventing costly repairs

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The mounting device is designed as a relatively simple, cost-effective component compared to the expensive standing seam panels. By using a less costly mounting system that can be easily replaced or adjusted, the overall installation cost is reduced without compromising the longevity and value of the premium building surface

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

3Productivity

If traditional mounting methods are used, then installation is faster, but alignment precision and grounding reliability are insufficient

Engineering Contradiction:

Improveinstallation speedVSAvoidalignment precision and grounding reliability

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The mounting device incorporates pre-positioned engagement members and alignment features that are prepared in advance during manufacturing. The engagement members are pre-configured to match the panel edge geometry, and the mounting plate includes pre-drilled holes and grounding contact points, allowing for quick and precise installation without time-consuming field adjustments

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The mounting system includes self-aligning features where the engagement members automatically position themselves on the panel edges, and the mounting plate self-positions relative to the panels through its geometric design. This self-alignment mechanism ensures precise positioning and reliable grounding contacts without requiring complex external alignment tools or procedures

Inventive Principle:

Principle #25Self-service

Data Source

PatentUS8627617B2Photovoltaic module mounting assembly

Publication Date: 2014.01.14 RMH TECH LLC

AI summary

A mounting assembly (70c) for installing solar cell or photovoltaic modules (58) on a building surface (34) is disclosed. The mounting assembly (70c) includes a mounting device (74), a stud (114) that may be threaded to the mounting device (74), a clamping member (142) that may be positioned on the stud (114), and a nut (128) that may be threaded onto the stud (114) to secure the clamping member (142) to the mounting device (74). A mounting plate (110′) is disposed somewhere between the clamping member (142) and the mounting device (74). This mounting plate (110′) includes a raised structure or dome (174) on its upper surface (170) for positionally registering modules (58) thereto, a plurality of grounding projections (172) on this same upper surface (170), and a plurality of wiring tabs or clips (178) on its lower surface (176).