Waterproofing mounting system for attaching solar modules to a roof
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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 also limit layout possibilities and increase the risk of leaks and complex grounding, making them inefficient and difficult to retrofit or maintain.
Innovation Solution
A rail-less PV module mounting system that uses a base mount assembly with a block slider and 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.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional rail mounting structures are used to support PV modules, then structural stability is improved, but material cost and device complexity increase significantly
Solution Approach 1:
The patent removes the rail component from the mounting system entirely. Instead of using traditional rails to support PV modules, the invention uses direct mounting brackets attached to roof structure, eliminating the need for complex rail assemblies while maintaining structural stability through simplified attachment points.
Solution Approach 2:
The mounting system is divided into independent modular units (mounting brackets) that can be individually installed at each PV module location. This segmentation replaces the continuous rail structure with discrete mounting points, reducing overall system complexity while maintaining local structural support where needed.
2Strength
If rail mounting structures are used, then PV module support is improved, but installation time and labor cost increase
Solution Approach 1:
The system uses independent mounting brackets for each PV module rather than installing continuous rails first. This allows installers to work on individual modules independently, parallelizing the installation process and significantly reducing total installation time while maintaining adequate support for each module.
Solution Approach 2:
The mounting brackets are pre-assembled with all necessary attachment components before installation. This preliminary preparation eliminates on-site assembly steps and reduces installation time, as each bracket is ready-to-install with integrated fastening mechanisms.
3Reliability
If multiple penetrations per mount are used in traditional systems, then grounding and electrical connection are improved, but waterproofing reliability deteriorates
Solution Approach 1:
The mounting bracket integrates grounding lugs and electrical connection points into the same structural component that provides mechanical support. This merging allows grounding functionality to be achieved through the existing single penetration point, eliminating additional penetrations that would compromise waterproofing while maintaining grounding reliability.
Solution Approach 2:
The mounting bracket serves multiple functions simultaneously: structural support, electrical grounding, and wire management. This multi-functionality is achieved within a single penetration assembly, reducing the total number of penetrations needed while maintaining all necessary electrical connections and grounding paths.
4Stability of the object's composition
If rail-based mounting systems are used, then PV array layout flexibility is limited, but structural integrity is maintained
Solution Approach 1:
The independent mounting bracket design allows each PV module to be positioned independently without being constrained by continuous rails. This segmentation provides flexibility to accommodate roof obstructions, irregular roof geometries, and various array layouts while each bracket maintains local structural integrity through direct attachment to the roof structure.
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.