Rail-less PV Module Mounting System with 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, 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 expensive.
Innovation Solution
A rail-less PV module mounting system that uses a base mount assembly with a clamp assembly for corner-to-corner coupling, reducing material and labor costs, and allowing for easy installation and adjustment, with a single grounding lug and elevated seal for waterproofing, enabling efficient installation on various roof types without cutting shingles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional rail mounting systems are used, then PV modules can be securely mounted to the roof structure, but material costs and installation complexity increase significantly
Solution Approach 1:
The mounting system is divided into discrete, modular components including individual mounts that attach to specific roof penetrations and clips that connect PV modules to these mounts. This segmentation allows for simplified installation and reduced overall system complexity while maintaining secure mounting through standardized connection points.
Solution Approach 2:
The traditional rail component is completely removed from the mounting system. Instead of using continuous rails that span across the roof, the invention extracts this element and replaces it with discrete mounts and clips, eliminating the complexity associated with rail installation, adjustment, and securing while achieving the same structural support function.
2Strength
If conventional rail mounting systems are used, then PV modules can be mounted to the roof structure, but installation time and labor costs increase
Solution Approach 1:
The mounts are pre-attached to the roof structure at predetermined locations before PV module installation. This preliminary action eliminates the time-consuming steps of measuring, positioning, and securing rails during the actual PV module installation process, significantly reducing on-site installation time while ensuring proper mounting security.
Solution Approach 2:
The system incorporates adjustable clips that can be quickly positioned and secured to accommodate variations in roof surfaces and PV module dimensions. This dynamic adjustment capability allows installers to rapidly adapt to different installation scenarios without requiring complex measurements or custom fabrication, reducing installation time while maintaining secure mounting.
3Strength
If conventional rail mounting systems are used, then PV modules can be mounted to the roof structure, but material costs and shipping costs increase
Solution Approach 1:
The system uses simple, inexpensive discrete mounts and clips made from cost-effective materials rather than expensive continuous rails. These individual components can be manufactured more economically and require less material overall, reducing both material costs and shipping costs while providing adequate mounting security for PV modules.
Solution Approach 2:
Instead of using uniform rails throughout the entire array, the invention applies mounting components only at specific local points where PV modules need attachment. This localized approach uses materials only where necessary, reducing overall material quantity and associated costs while maintaining secure mounting at each installation point.
4Strength
If conventional rail mounting systems are used, then PV modules can be mounted to the roof structure, but waterproofing reliability decreases due to multiple penetrations
Solution Approach 1:
The mounting system uses discrete mounts positioned at specific roof penetrations rather than continuous rails that require multiple attachment points. This segmentation allows for fewer, more strategically placed penetrations, each sealed with dedicated waterproofing components, thereby improving overall waterproofing reliability while maintaining secure PV module mounting.
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.