Rail-Less PV Roof Mounting With Corner Coupling and Waterproof Seals
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Solution Overview
Problem
Conventional photovoltaic (PV) module mounting systems require excessive materials, labor, and time for installation, with complex designs that increase costs and difficulties in working around roof obstructions, and lack efficiency in handling snow and wind loads, while also being difficult to retrofit and maintain.
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 needs, simplifying installation, and allowing for easy adjustment and maintenance, with a single grounding lug and elevated seal for waterproofing, enabling efficient installation on various roof types.
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 usage increases and shipping costs increase
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 intermediate rails, thereby reducing material usage while maintaining mounting capability.
Solution Approach 2:
The clamp assembly serves multiple functions: it provides mechanical attachment, electrical grounding, and structural support all in one component. This multi-functionality eliminates the need for separate rails and grounding lugs, reducing overall material quantity while ensuring reliable mounting.
2Reliability
If conventional rail mounting systems are used, then PV modules can be mounted on roof structures, but device complexity increases and installation time increases
Solution Approach 1:
The patent merges the mounting bracket, grounding lugs, and structural support functions into a single integrated clamp assembly. This consolidation reduces device complexity by eliminating multiple separate components (rails, brackets, lugs) while maintaining all necessary mounting capabilities.
Solution Approach 2:
The clamp assembly is designed as a universal component that performs multiple functions simultaneously: mechanical attachment to roof structures, electrical grounding through integrated lugs, and structural support for PV modules. This multi-functionality simplifies the overall system while ensuring reliable mounting.
3Reliability
If conventional rail mounting systems are used, then PV modules can be mounted on roof structures, but labor time increases and installation costs increase
Solution Approach 1:
The mounting system is segmented into independent clamp assemblies that can be installed individually at each PV module location. This modular approach allows installers to work on one module at a time without assembling long rails first, significantly reducing installation time and labor requirements.
Solution Approach 2:
The clamp assemblies are pre-configured with integrated grounding lugs and attachment mechanisms before installation. This preliminary preparation eliminates the need for on-site assembly of complex rail structures and grounding systems, allowing for rapid installation directly onto roof structures.
4Reliability
If conventional rail mounting systems are used, then PV modules can be mounted on roof structures, but the system becomes difficult to work around roof obstructions
Solution Approach 1:
The system uses independently installable clamp assemblies rather than continuous rails. This segmentation allows installers to easily navigate around roof obstructions like vents and skylights by simply skipping or adjusting individual clamp locations without disrupting the entire mounting structure.
Solution Approach 2:
The clamp assemblies are designed with adjustable positioning capabilities, allowing them to be dynamically placed at optimal locations that accommodate roof obstructions. The modular nature enables flexible configuration to adapt to various roof layouts and obstacles.
5Reliability
If conventional rail mounting systems are used, then PV modules can be mounted on roof structures, but waterproofing quality decreases and leak risk increases
Solution Approach 1:
The patent removes the multiple roof penetrations required by rail systems and replaces them with a single integrated penetration point per clamp assembly. This extraction of unnecessary penetration points directly reduces leak risk and improves waterproofing quality while maintaining mounting capability.
Solution Approach 2:
The clamp assembly integrates the mounting function with a single unified penetration point that incorporates both structural attachment and electrical grounding. This consolidation reduces the number of separate penetration points needed, thereby improving waterproofing quality and reducing leak risk.
Data Source
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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.