Rail mounting apparatus, system and method of securing devices to a structure
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Solution Overview
Problem
Existing rail mounting systems for solar panels require complex and time-consuming processes for attaching and removing channel nuts, which can lead to installation inefficiencies and safety hazards due to the need for simultaneous vertical and rotational motions, and the risk of errors from misalignment or improper fastener placement.
Innovation Solution
A rail mounting system with a channel nut and biasing element that allows for quick snap-in installation and secure retention, using a cross-sectional profile with recesses and flanges to facilitate easy alignment and positioning, and a biasing element that aids in maintaining the channel nut's position during installation, reducing the need for manual holding and enhancing safety.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional fastener and nut attachment systems are used, then the rail can be secured to the structure, but the installation process becomes time-consuming and complex due to requiring simultaneous vertical and rotational motions
Solution Approach 1:
The attachment system is segmented into distinct functional components: the rail with channel, the channel nut with biasing element, and the fastener. This segmentation allows each component to perform its specific function independently, eliminating the need for complex simultaneous motions and reducing installation time while maintaining securing reliability.
Solution Approach 2:
The biasing element is pre-loaded in the channel nut before installation. This preliminary action stores mechanical energy that automatically engages the fastener with the rail during insertion, eliminating the need for manual simultaneous vertical and rotational motions and significantly reducing installation time.
2Reliability
If traditional attachment systems requiring alignment and sliding are used, then the rail can be secured, but additional time is required for aligning the channel nut profile to the channel and inserting it
Solution Approach 1:
The biasing element automatically performs the alignment and engagement function. When the channel nut is inserted into the rail, the pre-loaded biasing element self-adjusts to align the fastener with the channel and pushes the fastener into engagement, eliminating the need for manual alignment operations and improving ease of insertion while maintaining attachment reliability.
3Reliability
If traditional fastener systems are used, then the rail can be secured to the structure, but removing fasteners requires access to the open end of the channel which complicates the process
Solution Approach 1:
The biasing element is designed to be compressed during installation, storing energy that locks the fastener in place. For removal, the process is inverted: applying force in the opposite direction compresses the biasing element in reverse, automatically releasing the fastener from the channel. This inversion principle allows fastener removal from any position along the rail, improving ease of repair while maintaining securing reliability.
4Manufacturing precision
If manual holding of channel nut is required during installation, then proper positioning can be maintained, but the installer's hand is occupied reducing safety on the structure
Solution Approach 1:
The biasing element provides self-positioning and self-holding functionality during installation. The pre-loaded spring automatically maintains the channel nut in the correct position as it is inserted into the rail, eliminating the need for manual holding. This frees the installer's hand for safety purposes while maintaining positioning precision through the mechanical action of the biasing element.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The system significantly reduces installation time, improves safety by freeing up the installer's hand, and simplifies the placement and removal of fasteners, thereby enhancing the efficiency and safety of the installation process.
Implementation Method 1
a biasing element configured to elastically deform when the channel nut is inserted into an opening of the rail
Data Source
AI summary
A retention apparatus, system and method is useful for attaching items, panels or other devices to a rail formed in longitudinal lengths and configured with a cross-sectional profile having multiple cooperating structures between the rail and a channel nut. Self-aligning, mating structures include a recess formed between a tooth and shelf on an interior first channel portion of the rail and a flange of the channel nut with concurrent mating of an anchor latch of the rail and a hook flange on the channel nut. Latching of the channel nut is accomplished initially by compression of the biasing element as the channel nut is inserted and then, upon release, biasing element-induced movement of the channel nut into a latching position. Grounding spikes on the biasing element form electrical contact points between the rail, the clamp and the frame of the solar panel or other device.