Rail-Less PV Roof Mounting With Corner Clamp Coupling
Find Innovative SolutionsGenerate Solutions
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 block slider and 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 and maintenance without the need for additional structural support.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional rail mounting systems are used, then PV modules can be mounted on roof structures, but material costs and shipping costs increase significantly
Solution Approach 1:
The patent removes the rail component entirely from the mounting system, extracting only the essential mounting function. The clamp assembly directly attaches PV modules to roof structures without requiring rails, eliminating material costs associated with rail production and shipping while maintaining mounting capability.
Solution Approach 2:
The patent employs simpler, less expensive clamp assemblies that can be easily installed and removed without the need for durable, expensive rail structures. The clamp design uses basic fastening mechanisms rather than complex rail systems, reducing overall material costs.
2Reliability
If conventional rail mounting systems are used, then PV modules can be secured to roof structures, but installation time and labor costs increase
Solution Approach 1:
The patent divides the mounting system into independent clamp assemblies that can be installed individually at each PV module location rather than installing long continuous rails. This segmentation allows installers to work on one module at a time, reducing overall installation time and allowing flexible scheduling without requiring continuous roof access.
Solution Approach 2:
The clamp assembly incorporates adjustable and movable components that can be quickly positioned and secured without complex alignment procedures required by rigid rail systems. The dynamic design allows for rapid installation and adjustment during the mounting process.
3Reliability
If conventional rail mounting systems are used, then PV modules can be mounted, but the system becomes complex with multiple components
Solution Approach 1:
The patent combines multiple functions into the single clamp assembly: mechanical attachment to the roof, electrical grounding through the grounding lug, and PV module securing all in one component. This merging eliminates the need for separate rails, mounting brackets, and grounding components, significantly reducing system complexity.
Solution Approach 2:
The clamp assembly is designed as a universal component that performs multiple functions simultaneously: structural support, electrical grounding, and module attachment. The single clamp assembly with integrated grounding lug serves all mounting requirements without needing additional specialized components.
4Reliability
If conventional rail mounting systems are used, then PV modules can be installed on roofs, but the risk of leaks increases due to multiple penetrations
Solution Approach 1:
The patent extracts the grounding function from separate grounding lugs and integrates it into the clamp assembly itself. The grounding lug is built into the clamp, eliminating the need for additional penetration points in the roof for grounding purposes, thereby reducing leak risk while maintaining grounding capability.
5Reliability
If conventional rail mounting systems are used, then PV modules can be mounted, but adaptability to different roof layouts is limited
Solution Approach 1:
The patent uses segmented clamp assemblies that can be independently positioned at different locations on the roof without being constrained by continuous rail structures. This allows flexible adaptation to various roof layouts, obstacles, and PV module arrangements, as each clamp can be placed optimally for its specific location.
Data Source
AI summary
A rail-less roof mounting system for installing photovoltaic (PV) modules on a roof structure comprises a base mount assembly that engages with a clamp assembly and attaches to the roof structure. The base mount assembly comprises a base member having a waterproof means, a block slider, a top slider and a covering means. An elevated seal portion of a block slider includes a borehole to receive the waterproof means. A vertical engaging portion of the block slider is attached with a sliding seal member of the top slider. The clamp assembly includes a clamp member and a plate member and the clamp member is attached with a track of the top slider. The clamp member interlocks the PV modules to provide a corner-to-corner coupling arrangement, which enables the connection of PV module corners to adjacent PV module corners by sandwiching above and beneath frame members of the PV modules.