PV Panel Mounting Rails With Top-Access Adjustable Clamps
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Solution Overview
Problem
Existing mounting systems for photovoltaic panels struggle to provide secure and adjustable support on uneven surfaces without access to the back of the panels, requiring numerous hardware components and complicating installation and removal processes.
Innovation Solution
A mounting system utilizing photovoltaic panel frames with inward extensions, panel support rails, and novel clamps with lead screws, allowing for top-down or bottom-up installation and adjustment, accommodating irregular surfaces and panel sizes, with universal hardware for versatile configurations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional mounting systems are used to secure photovoltaic panels on uneven surfaces, then the panels can be firmly attached, but the system requires numerous hardware components and complex assembly procedures
Solution Approach 1:
The patent combines multiple mounting functions into a single integrated bracket assembly that includes the mounting bracket, support rail, and clamping mechanism as one unified component. This merging eliminates the need for numerous separate hardware pieces while maintaining secure attachment to uneven surfaces
Solution Approach 2:
The mounting bracket is designed with universal adaptability to work with various panel sizes, shapes, and surface irregularities through adjustable features. The single bracket assembly performs multiple functions including positioning, clamping, and accommodating surface variations, replacing numerous specialized components
2Adaptability or versatility
If traditional mounting systems are used to accommodate irregular surfaces, then the panels can be mounted on various surfaces, but the installation and removal processes become time-consuming
Solution Approach 1:
The mounting bracket incorporates dynamic adjustment mechanisms including movable clamps and adjustable positioning features that can be quickly modified during installation. This allows rapid adaptation to irregular surfaces without time-consuming custom fitting, while the quick-release mechanism enables fast removal when needed
3Reliability
If access is required to the back of photovoltaic panels for mounting, then secure attachment can be achieved, but installation becomes impossible where back access is unavailable
Solution Approach 1:
The mounting bracket is designed to attach to the front or side edges of the panel frame rather than requiring back access. The bracket engages with the panel frame extensions and secures the panel through a front-facing clamping action, inverting the traditional mounting approach that requires rear access
4Adaptability or versatility
If multiple hardware components are used to provide adjustable mounting configurations, then versatility in panel orientation and size is achieved, but the part count and assembly complexity increase
Solution Approach 1:
The patent integrates multiple adjustable components into a single modular bracket assembly that provides configuration flexibility through internal adjustment mechanisms rather than requiring multiple separate parts. The unified design maintains versatility while minimizing the number of discrete components needed
Data Source
AI summary
A mounting system for mounting photovoltaic panels on a support structure. The mounting system comprises photovoltaic panel frames in which the photovoltaic panels are mounted, panel support rails, and mounting brackets or cross beams for supporting the panel support rails. The panel frames have inwardly extending panel frame extensions on their back side. The panel support rails are mounted on the support structure with either pivoting brackets or cross beams. In either case, the support rails have pairs of stationary clamps and movable clamps with clamp lips that engage the panel frame extensions of the panel frames.