Rail-Free PV Module Mounting Bracket for Tool-Free Roof Installation
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Solution Overview
Problem
Traditional rail-free PV mounting systems are time-consuming to install and costly due to the need for flashings, which require complex site preparation and can create potential leak points, and they struggle with planar variations in roof surfaces, leading to inefficiencies and increased material costs.
Innovation Solution
A PV module mounting system featuring a mounting bracket with a curved cross-sectional shape and a hanger bolt system that allows for tool-free installation and angular adjustment, accommodating roof surface irregularities through a washer and threaded knob mechanism, and a coupling device for securing PV modules without the need for extensive tooling or custom features.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If flashings are used in mounting systems, then water leak prevention is improved, but installation time increases and material costs increase
Solution Approach 1:
The patent removes the flashing component entirely from the mounting system, replacing it with a mounting bracket that directly attaches to the roof structure. This extraction of the unnecessary component eliminates the time-consuming installation steps while maintaining structural integrity and water leak prevention through the redesigned bracket system.
Solution Approach 2:
The mounting bracket is designed to perform multiple functions simultaneously: it provides structural support for PV modules, creates water diversion paths, and secures modules to the roof structure. By combining these functions into a single component, the system eliminates the need for separate flashings while maintaining reliability and reducing installation complexity.
2Reliability
If flashings are used in mounting systems, then water leak prevention is improved, but material costs increase
Solution Approach 1:
The patent eliminates the flashing component from the system, removing the associated material costs. The mounting bracket is designed to perform the water protection function that previously required separate flashing materials, thereby reducing overall material requirements and cost.
Solution Approach 2:
The patent combines the water protection function previously provided by flashings into the mounting bracket itself. This merging of functions reduces the total number of components and material types required, lowering material costs while maintaining the necessary reliability for water leak prevention.
3Reliability
If traditional mounting systems are used, then secure module attachment is improved, but device complexity increases
Solution Approach 1:
The patent removes unnecessary components from traditional mounting systems, including flashings and complex multi-part bracket assemblies. The simplified design uses a single integrated mounting bracket that directly attaches to the roof, reducing device complexity while maintaining secure module attachment through optimized bracket geometry and attachment mechanisms.
4Loss of time
If mounting brackets are used without flashings, then installation time is reduced, but water leak prevention capability is worsened
Solution Approach 1:
The mounting bracket is designed to perform multiple functions including structural support, water diversion, and roof penetration protection. By integrating these functions into a single component, the system achieves fast installation without flashings while maintaining water leak prevention capability through the bracket's built-in water management features.
Data Source
AI summary
A photovoltaic (PV) module mounting system including a mounting bracket that has a curved mating surface extending as an arch between a pair of flat mounting feet portions. The mounting bracket supports a PV module coupling device. A hanger bolt is provided that has a first threaded portion adapted to engage a roof surface and a second threaded portion for passing through the curved mating surface of the mounting bracket. A threaded knob is adapted to mate with the second threaded portion of the hanger bolt.