Rail-Less PV Module Mounting Using Corner-to-Corner Coupling
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Solution Overview
Problem
Conventional photovoltaic (PV) module mounting systems require excessive materials, labor, and time for installation, often leading to high costs and inefficiencies due to the use of rails, which also pose challenges in design, engineering, and maintenance, particularly on roof structures with obstructions.
Innovation Solution
A rail-less PV module mounting system that uses a base mount assembly with a clamp assembly for corner-to-corner coupling, eliminating the need for additional structural support, reducing material and labor costs, and allowing for easier installation and maintenance by providing a single grounding lug and elevated seal for waterproofing, along with adjustable features for vertical leveling and easy removal of individual modules.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional rail mounting structures are used, then PV modules can be mounted on roof structures, but material costs and shipping costs increase due to additional rails required
Solution Approach 1:
The patent removes the rail component from the mounting system entirely. Instead of using rails to support PV modules, the invention uses discrete mounting brackets that attach directly to the roof structure at each module location, eliminating the need for extensive rail materials and their associated shipping costs
Solution Approach 2:
The mounting system is divided into independent modular units (mounting brackets) that can be installed individually at each PV module location rather than requiring a continuous rail structure, reducing overall material quantity while maintaining mounting capability
2Reliability
If conventional rail mounting structures are used, then PV modules can be mounted on roof structures, but labor time and installation cost increase significantly
Solution Approach 1:
The system uses independently installable mounting brackets for each PV module rather than requiring installation of continuous rails first, then mounting modules to rails. This segmented approach allows installers to work on individual modules independently, reducing overall installation time and complexity
Solution Approach 2:
The mounting brackets are pre-configured with all necessary attachment components (roof anchors, module clamps, grounding lugs) integrated into single units, eliminating the need for on-site assembly of multiple separate rail components and reducing installation time
3Reliability
If conventional rail mounting structures are used, then PV modules can be mounted on roof structures, but the system becomes complex with multiple components including rails, mounts, grounding lugs, and wire management
Solution Approach 1:
The mounting bracket integrates multiple functions into a single component: structural support for the PV module, roof penetration anchoring, electrical grounding connection, and wire management pathways. This consolidation eliminates the need for separate rails, mounting brackets, grounding lugs, and wire management components, significantly reducing system complexity
Solution Approach 2:
The mounting bracket is designed as a universal component that performs multiple functions simultaneously (mechanical support, grounding, wire routing), replacing the need for multiple specialized components in conventional rail systems and simplifying both design and installation
4Reliability
If conventional rail mounting structures are used, then PV modules can be mounted on roof structures, but the system weight exceeds 300 Lbs for a 5 kW system
Solution Approach 1:
The heavy rail components are completely removed from the system. The mounting brackets use minimal material necessary for direct roof-to-module attachment, eliminating the weight of extensive rail structures while maintaining adequate structural support capability
Solution Approach 2:
The mounting system is segmented into small, lightweight brackets installed only where needed at each module location rather than requiring continuous heavy rail structures spanning the entire array, significantly reducing overall system weight
5Reliability
If conventional rail mounting structures are used, then PV modules can be mounted on roof structures, but the system requires 5 penetrations per mount with substandard waterproofing
Solution Approach 1:
The mounting bracket consolidates roof penetration points and integrates superior waterproofing seals at each penetration location. The design minimizes the number of penetrations required per module while ensuring each penetration is properly sealed, improving waterproofing quality compared to conventional rail systems with multiple penetration points
6Reliability
If conventional rail mounting structures are used, then PV modules can be mounted on roof structures, but the system requires specifically engineered PV modules with frames and grooves
Solution Approach 1:
The mounting bracket is designed as a universal adapter that can accommodate various PV module types and frame configurations. The bracket's adjustable clamping mechanism and multiple attachment point options allow it to work with standard framed modules, frameless modules, and different module sizes without requiring specifically engineered custom modules
Data Source
AI summary
A roof mounting system for the attachment of an article to a roof, the system comprising a plurality of PV modules each having at least one corner and a frame member, a flashing member having a top surface; an upstanding sleeve attached to the top surface of the flashing member; an elevated water seal having a borehole formed therethrough, the elevated water seal further comprising at least one screw for providing a waterproof seal between the article and the roof structure; and whereby the plurality of PV modules are interlocked in a way to provide a corner-to-corner coupling arrangement supported above the roof through the frame members of the plurality of PV modules.