Replacement Tile Mount for Waterproof Solar Panel Installation
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Solution Overview
Problem
Existing solar panel mounting systems for tiled roofs are complex and time-consuming to install, requiring the removal of roofing tiles and lack efficient waterproofing solutions.
Innovation Solution
A one-piece, monolithic tile support mount with a custom-designed aperture-less replacement tile and a magnetic positioning tool for precise alignment, providing a rigid structural support and waterproof sealing system for solar panels on tiled roofs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional solar panel mounting systems are used on tiled roofs, then structural support is provided, but installation is complex and time-consuming requiring tile removal
Solution Approach 1:
The patent combines the mounting structure and replacement tile into a single integrated unit. The tile mount includes a base portion that secures to the roof, a vertical portion extending upward, and a cap portion that receives the solar panel mounting bracket, all integrated with a replacement tile that fits over the structure. This merging eliminates the need for separate tile removal and mounting steps, directly improving installation productivity while reducing complexity.
Solution Approach 2:
The mounting structure is pre-assembled with the replacement tile before installation on the roof. The base portion, vertical portion, cap portion, and replacement tile are configured as a complete unit that can be installed in one operation. This preliminary assembly eliminates the need for on-site tile removal and sequential assembly steps, significantly improving installation speed and reducing complexity.
2Reliability
If replacement tiles are used to cover mounting structures, then waterproofing is improved, but alignment and positioning precision is difficult to achieve
Solution Approach 1:
The patent introduces alignment features as intermediary elements between the mounting structure and replacement tile. These include protrusions on the mounting structure that fit into corresponding recesses in the tile, or vice versa, ensuring precise alignment during installation. This intermediary alignment mechanism maintains waterproofing reliability while solving the positioning precision problem.
Solution Approach 2:
The replacement tile and mounting structure incorporate localized alignment features at specific positions rather than relying on overall tile dimensions. These local features such as alignment pins, grooves, or raised edges provide precise positioning points that ensure correct tile placement while maintaining the overall waterproofing integrity of the assembly.
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 solution simplifies the installation process by allowing for direct attachment of solar panels to the roof without removing tiles, ensuring a secure and waterproof connection, thereby reducing installation time and costs while maintaining structural integrity.
Implementation Method 1
a magnetic positioning tool tactile based aperture location that provides proper alignment of a drill bit when drilling or punching holes through the replacement tile
Data Source
AI summary
A one-piece, monolithic tile support mount attaches to a roof and provides rigid structural support for a lateral attachment bar or L-foot that is used to hold a height-adjustable mounting mechanism or mounting rail, which is used to attach solar photovoltaic panels to the roof of a roof covered with roofing tiles. A custom-designed, sheet-metal or polymer, aperture-less replacement tile is mounted between the lateral attachment bar or the L-foot and the tile support mount. Also provided is a compact, magnetic positioning tool that provides proper alignment of a drill bit when drilling or punching holes through the replacement tile.