Rail-Less Clamp Assembly for Corner-to-Corner PV Module Mounting
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Solution Overview
Problem
Conventional photovoltaic (PV) module mounting systems require excessive materials, labor, and time for installation, and are costly due to the use of rails, which limits layout flexibility and increases material and engineering costs, while also posing challenges with waterproofing and handling roof obstructions.
Innovation Solution
A rail-less roof mounting system that uses a base mount assembly with a block slider and clamp assembly for corner-to-corner coupling of PV modules, eliminating the need for additional structural support, reducing material and labor costs, and providing improved waterproofing and flexibility in installation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional rail mounting systems are used to support PV modules, then structural stability is improved, but material cost and device complexity increase significantly
Solution Approach 1:
The mounting system is divided into discrete clamp assemblies that can be independently installed at each PV module location, eliminating the need for continuous rails. Each clamp assembly includes a base member with penetrating fasteners and a top member that clamps to the PV module frame, allowing modular installation and reducing overall system complexity while maintaining structural stability through distributed attachment points.
Solution Approach 2:
The rail component is completely removed from the mounting system. Instead of using rails to support and connect PV modules, the invention directly clamps PV modules to the roof structure using standalone clamp assemblies. This extraction of the rail element simplifies the system by eliminating complex rail connections, adjustments, and support structures while maintaining adequate structural support through direct roof attachment.
2Strength
If rails are used to mount PV modules, then structural support is provided, but installation time and labor cost increase
Solution Approach 1:
The mounting system uses independent clamp assemblies that can be quickly installed at each PV module location without requiring assembly of long rail sections. Each clamp is a self-contained unit with pre-configured fasteners and clamping mechanisms, allowing installers to rapidly attach one clamp per module without complex alignment procedures required by rail systems.
Solution Approach 2:
The clamp assemblies are pre-configured with all necessary fasteners, sealing elements, and clamping components integrated into single units. The base member includes pre-attached penetrating fasteners and waterproofing elements, eliminating the need for multiple separate installation steps required by rail systems. This preliminary integration of components significantly accelerates installation while maintaining structural support.
3Strength
If multiple penetrations per mount are used in traditional rail systems, then structural attachment is secured, but waterproofing reliability deteriorates
Solution Approach 1:
Multiple fastening functions and waterproofing elements are merged into a single integrated clamp assembly. The base member combines penetrating fasteners, sealing washers, and mounting hardware into one unified component that creates a single consolidated penetration point through the roof. This merging maintains secure structural attachment while improving waterproofing by eliminating multiple separate penetration points that would each require individual sealing.
Solution Approach 2:
The base member serves multiple functions simultaneously: it provides structural penetration through the roof, incorporates waterproof sealing elements, attaches the clamp assembly to the roof structure, and positions the clamping mechanism. This multi-functionality consolidates what would otherwise require multiple separate components and penetration points into a single universal mounting element that secures attachment while protecting against water infiltration.
4Ease of manufacture
If traditional rail mounting systems are used, then PV modules can be mounted, but adaptability to roof obstructions and layout flexibility decrease
Solution Approach 1:
The system uses discrete, independently positionable clamp assemblies rather than continuous rails that must span entire arrays. Each clamp can be individually positioned to accommodate roof features such as vents, skylights, or chimneys, allowing the PV array layout to adapt around obstructions without requiring complex rail configurations or custom-fabricated rail sections.
Solution Approach 2:
The clamp assemblies provide adjustable positioning capabilities along the PV module frames, allowing installers to dynamically adjust clamp locations to accommodate varying roof conditions and obstructions. The modular nature of the clamps enables flexible array configurations that can be easily modified during installation to optimize layout around roof features, unlike rigid rail systems that require precise pre-planning and fabrication.
Data Source
AI summary
A rail-less roof mounting system for installing photovoltaic (PV) modules on a roof structure comprises a base mount assembly that engages with a clamp assembly and attaches to the roof structure. The base mount assembly comprises a base member having a waterproof means, a block slider, a top slider and a covering means. An elevated seal portion of a block slider includes a borehole to receive the waterproof means. A vertical engaging portion of the block slider is attached with a sliding seal member of the top slider. The clamp assembly includes a clamp member and a plate member and the clamp member is attached with a track of the top slider. The clamp member interlocks the PV modules to provide a corner-to-corner coupling arrangement, which enables the connection of PV module corners to adjacent PV module corners by sandwiching above and beneath frame members of the PV modules.