Rail assembly with invertible side-mount adapter for direct and indirect mounting applications
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Solution Overview
Problem
The high cost of standing seam metal panels and the complexity of installing structures like heating, air conditioning, and photovoltaic systems on building surfaces defined by metal panels, particularly due to the lack of efficient mounting solutions for various panel configurations such as trapezoidal rib and corrugated panels.
Innovation Solution
A rail assembly designed to be attachable to building surfaces, featuring a one-piece body with specific pocket and channel configurations that allow secure attachment to various types of metal panel protrusions, including standing seams, trapezoidal ribs, and corrugated panels, enabling flexible installation of attachments like air conditioning units and solar panels.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If standing seam metal panels are used to define building surfaces, then the aesthetic quality and durability are improved, but the cost increases significantly
Solution Approach 1:
The patent employs a removable and reusable mounting rail system that can be detached and reinstalled on different panel configurations. This allows the use of less expensive panel types while maintaining the ability to mount equipment, effectively reducing the overall system cost while preserving durability through the reusable mounting infrastructure.
Solution Approach 2:
The mounting rail is designed with multiple attachment configurations (direct mounting to standing seams, indirect mounting via adapters to trapezoidal ribs and corrugated panels) that enable a single rail design to work across different panel types. This universality allows builders to choose cost-effective panel options without sacrificing mounting capability or durability.
2Adaptability or versatility
If mounting structures are installed on building surfaces with various metal panel configurations, then the functionality of heating, air conditioning, and photovoltaic systems is improved, but the installation complexity increases due to lack of efficient mounting solutions
Solution Approach 1:
The mounting system is divided into modular components: a universal mounting rail and separate adapter types for different panel configurations. This segmentation allows installers to select only the specific adapter needed for their panel type, reducing overall installation complexity while maintaining versatility across heating, air conditioning, and photovoltaic applications.
Solution Approach 2:
Instead of designing different mounting structures for each panel type, the patent inverts the approach by designing a universal rail that adapts to various panel configurations through interchangeable adapters. This inversion simplifies the core mounting mechanism while maintaining adaptability to trapezoidal ribs, corrugated panels, and standing seams.
3Ease of operation
If direct mounting is used to attach rails to standing seam panels, then the installation simplicity is improved, but the adaptability to other panel configurations deteriorates
Solution Approach 1:
The mounting system transitions from a static direct-mounting design to a dynamic adaptive system. The rail maintains its simple direct-mounting interface with standing seams while incorporating removable adapters that can be attached or detached based on the panel configuration, thus preserving installation simplicity while enhancing adaptability.
Solution Approach 2:
Adapters serve as intermediary components between the universal mounting rail and various panel configurations. These adapters maintain the simplicity of the rail installation while extending compatibility to trapezoidal ribs and corrugated panels, effectively mediating between the simple mounting interface and diverse panel types.
4Adaptability or versatility
If indirect mounting with adapters is used to attach rails to building surfaces, then the adaptability to various panel configurations is improved, but the device complexity increases
Solution Approach 1:
The adapter design employs a nested structure where the adapter body contains integrated features for both panel attachment and rail mounting. This nesting consolidates multiple functions into a single compact component, reducing device complexity while maintaining adaptability to various panel configurations.
Data Source
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AI summary
A rail assembly (530) includes a rail (540) and an adapter (640). The adapter (640) may be slidably interconnected with the rail (540) via a first rail channel (604a) on a first rail side (600a) of the rail (540), and may also be slidably interconnected with the rail (540) via a second rail channel (604b) on a second rail side (600b) of the rail (540). The adapter (640) may be inverted (whether installed via the first rail channel (604a) or the second rail channel (604b)) between two different orientations that dispose a mounting flange (670) at different elevations to accommodate two different mounting configurations.