Rail-Pipe Brackets and Adjustable Clamps for Faster Solar Mounting
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Solution Overview
Problem
Existing ground-mount solar panel mounting systems are complex, increasing installation time and parts count, and often have less than ideal electrical bonding.
Innovation Solution
A solar panel mounting system that includes rail-pipe brackets and pipe clamps, which simplify assembly, reduce parts count, and facilitate electrical grounding through a multiple-tier hinge and pivotable threaded fasteners, as well as movable bonding pins.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional ground-mount solar panel mounting systems are used, then solar panels can be secured to rooftops or ground, but the system complexity increases and installation time increases
Solution Approach 1:
The patent combines multiple functions into integrated components. The rail-pipe bracket merges the function of securing rails to pipes with providing mounting points for solar panels. The pipe clamp combines clamping, positioning, and adjustment functions in a single component, eliminating the need for separate fasteners and alignment tools.
Solution Approach 2:
The mounting system components are designed to perform multiple functions. The adjustable pipe clamp can accommodate different pipe diameters and orientations while providing secure attachment. The rail-pipe bracket serves both as a structural connector and as a platform for solar panel installation, reducing the total number of components needed.
2Reliability
If traditional ground-mount solar panel mounting systems are used, then solar panels can be secured to rooftops or ground, but the parts count increases
Solution Approach 1:
The patent consolidates multiple separate parts into integrated components. The rail-pipe bracket combines the mounting bracket, fastening mechanism, and positioning features into a single piece. The pipe clamp integrates the clamping arms, adjustment mechanism, and locking features, eliminating the need for separate washers, nuts, and alignment tools.
Solution Approach 2:
The system is divided into modular components that can be independently installed and adjusted. The pipe clamp and rail-pipe bracket are separate modules that can be assembled in different configurations depending on the installation requirements, allowing for flexible assembly with fewer total parts.
3Reliability
If traditional ground-mount solar panel mounting systems are used, then solar panels can be secured to rooftops or ground, but electrical bonding becomes less than ideal
Solution Approach 1:
The patent integrates electrical bonding functionality into the mechanical mounting components. The rail-pipe bracket and pipe clamp incorporate conductive elements and bonding surfaces that simultaneously provide structural attachment and electrical grounding, eliminating the need for separate bonding wires or connectors.
4Reliability
If complex mounting systems are used, then solar panels can be secured, but installation time increases
Solution Approach 1:
The mounting components are pre-configured with integrated features that eliminate on-site adjustments. The pipe clamp includes pre-positioned adjustment mechanisms and the rail-pipe bracket has pre-formed mounting surfaces, allowing installers to simply assemble the components without complex alignment or multiple fastening steps.
Solution Approach 2:
By combining multiple functions into single components, the installation process is simplified from multiple sequential steps into fewer integrated actions. The unified design of the pipe clamp and rail-pipe bracket allows for faster assembly and reduction in the number of fastening operations required.
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 decreases installation complexity, reduces parts count, and simplifies electrical bonding, making it more efficient and effective for ground-mount and rooftop solar panel installations.
Implementation Method 1
The rail-pipe bracket secures the rail by spring tension
Implementation Method 2
uses clamping pressure to secure the pipe against the rail
Data Source
AI summary
Disclosed are devices that may include brackets and clamps for assembling mounting structures built from pipes and cross-braces. These mounting structures support solar panels. The devices may include a rail-pipe bracket that secures a rail to a pipe. The rail-pipe bracket may include openings for seating a pipe and include hooks for securing the rail. The devices may also include one or more pipe clamps that secure the pipes together. These pipe clamps are adjustable and may accommodate pipes of various sizes thanks to a multi-tier hinge structure.