Rail-Less Solar Module Mounting With Waterproof Roof Seals
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Solution Overview
Problem
Conventional photovoltaic (PV) module mounting systems require excessive materials, labor, and time for installation, often leading to high costs and inefficiencies, particularly due to the use of rails that complicate design, engineering, and installation, and are difficult to retrofit or adjust without damaging roofs.
Innovation Solution
A rail-less PV module mounting system that uses a base mount assembly with a clamp assembly for corner-to-corner coupling, eliminating the need for additional structural support, reducing material and labor costs, and allowing for easy installation and adjustment, with features like elevated seals for waterproofing and adjustable vertical leveling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If conventional rail mounting systems are used to support PV modules, then structural stability is improved, but device complexity and material usage increase significantly
Solution Approach 1:
The patent removes the rail component entirely from the mounting system, extracting only the essential function of supporting PV modules directly to the roof structure. This eliminates the complex rail assembly while maintaining structural stability through direct mounting brackets and simplified support mechanisms.
Solution Approach 2:
The mounting system is divided into independent, modular components that can be installed separately and configured in different patterns. Each mounting point operates independently, allowing flexible arrangement without requiring continuous rail structures, thereby reducing overall system complexity while maintaining stability.
2Reliability
If traditional rail mounting structures are installed, then PV module support is achieved, but installation time and labor costs increase
Solution Approach 1:
The mounting system incorporates adjustable and adaptable components that can be quickly configured for different roof types and module arrangements. The dynamic design allows installers to adapt to various conditions without time-consuming custom fabrication or complex assembly procedures, reducing installation time while maintaining reliable support.
Solution Approach 2:
The mounting brackets and support components are designed to be self-aligning and self-adjusting during installation, reducing the need for precise pre-measurement and complex alignment procedures. This self-service feature accelerates installation while ensuring proper PV module support.
3Strength
If rail-based mounting systems are used, then structural strength is improved, but material costs and shipping costs increase
Solution Approach 1:
The patent extracts and eliminates the rail component, which is the primary source of material consumption in traditional mounting systems. By removing this redundant structural element and using only essential mounting brackets and fasteners, the system maintains adequate structural strength while dramatically reducing material usage and associated costs.
Solution Approach 2:
Instead of using continuous rails that provide strength throughout their length, the patent applies structural strength locally at each mounting point where PV modules are attached to the roof. This localized approach provides sufficient strength for support while minimizing overall material consumption.
4Reliability
If conventional mounting structures with multiple penetrations are used, then secure attachment is achieved, but waterproofing reliability decreases
Solution Approach 1:
Instead of creating multiple penetration points that compromise the roof membrane, the patent inverts the approach by using mounting systems that attach to roof features (such as ridges, eaves, or existing structural elements) without penetrating the waterproof membrane. This maintains attachment security while eliminating water infiltration pathways.
Solution Approach 2:
The patent introduces intermediary mounting components that bridge the PV module support function and the roof structure without requiring direct penetration of the waterproof membrane. These intermediaries allow secure attachment while preserving the integrity of the roof's waterproofing system.
Data Source
AI summary
A roof mounting system for the attachment of an article to a roof, the system comprising a plurality of PV modules each having at least one corner and a frame member, a flashing member having a top surface; an upstanding sleeve attached to the top surface of the flashing member; an elevated water seal having a borehole formed therethrough, the elevated water seal further comprising at least one screw for providing a waterproof seal between the article and the roof structure; and whereby the plurality of PV modules are interlocked in a way to provide a corner-to-corner coupling arrangement supported above the roof through the frame members of the plurality of PV modules.