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Solution Overview
Problem
Existing photovoltaic module mounting systems are bulky, noticeable on existing roofs, require time-consuming installation processes, and increase labor costs due to precise measurement and numerous fasteners, discouraging their use as a power source.
Innovation Solution
A roof mounting system that integrates directly with roofing materials, using flexible flashing and bracket assemblies with biased clips to secure PV modules, allowing for faster installation and alignment without the need for additional fasteners.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If PV modules are installed on existing roofs with support structure and flashing over shingles, then the modules can be installed on existing roofs, but the appearance becomes bulky and noticeable
Solution Approach 1:
The mounting system is divided into separate components: a low-profile base plate that attaches to the roof, and a module support structure that rises only where needed. This segmentation allows the majority of the roof surface to remain flat and unobtrusive while providing elevated support only at mounting points.
Solution Approach 2:
The flashing components extend vertically in the third dimension to create waterproof barriers without increasing the horizontal footprint. By solving the waterproofing problem in the vertical dimension rather than requiring large horizontal flashings, the system maintains a low profile across the roof surface.
2Reliability
If traditional mounting systems use numerous fasteners and require precise measurement and alignment, then secure attachment is achieved, but installation time increases
Solution Approach 1:
The bracket assembly incorporates self-aligning features where the bracket automatically positions itself relative to the rail upon insertion. The clip engages with the rail in a self-locking manner that requires no additional alignment steps or tools, allowing installers to simply insert and secure components in sequence.
Solution Approach 2:
Multiple functions are combined into single components: the bracket serves as both the attachment point and alignment reference, while the clip provides both securing and positioning functions. This consolidation eliminates the need for separate alignment tools and multiple fastening operations.
3Reliability
If traditional PV module systems include underlayment materials installed prior to modules, then proper roof integration is achieved, but the system cannot be installed on existing roofs
Solution Approach 1:
The low-profile base plates and flashing components are pre-installed on the roof surface before module attachment. This preliminary installation creates a ready-made mounting infrastructure that integrates with the existing roof covering, eliminating the need for underlayment and enabling retrofits on completed roofs.
Solution Approach 2:
The flashing components utilize thin, flexible materials that can conform to existing roof surfaces and integrate seamlessly with shingles or tiles. These thin-film flashings provide waterproofing without adding significant thickness, allowing installation over completed roofing systems.
Data Source
AI summary
The present disclosure provides a bracket assembly for securing a photovoltaic (PV) module. The bracket assembly may include a bracket having a top portion and a bottom surface and a clip coupled to the bracket. The clip may include a hooked portion, wherein the clip is configured to be displaced by a PV module from a first position to a second position. The clip may be biased toward the first position, and the hooked portion may be configured to engage an edge feature of the PV module.