Skip rail system
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Solution Overview
Problem
Current solar mounting solutions using rails require two rails per row of solar modules, increasing installation time, labor, and the risk of roof leaks, necessitating a reduction in the number of rail rows for time and cost savings as well as risk reduction.
Innovation Solution
The Skip Rail Splice system allows for the installation of solar modules using a single row of rails for rows two and above by employing a skip rail splice configuration that secures solar modules with angled and horizontal members, utilizing bond pins for electrical bonding and clamping forces to secure the modules.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If two rails per row are used for mounting solar modules, then the structural stability and support for solar modules are improved, but the installation time and labor costs increase
Solution Approach 1:
The patent extracts and eliminates one of the two parallel rails from the mounting system. By using a single rail with optimized spacing and attachment points, the system maintains sufficient structural stability while removing the redundant second rail, thereby reducing installation time and labor requirements.
Solution Approach 2:
The single rail in the patent is designed to perform multiple functions that were previously distributed across two rails: providing structural support, enabling module attachment at multiple points, and ensuring proper spacing. This multi-functional design maintains stability while reducing component count.
2Strength
If two rails per row are used for mounting solar modules, then the support and securing capability are improved, but the number of roof penetrations increases leading to higher leak risk
Solution Approach 1:
The patent removes one rail from the mounting system, which directly reduces the number of roof penetrations required. Fewer penetrations mean fewer potential leak points, thereby reducing the risk of roof leaks while maintaining adequate support capability through the optimized single-rail configuration.
3Reliability
If two rails per row are used for mounting solar modules, then the mounting reliability is improved, but the installation labor costs increase
Solution Approach 1:
By eliminating one rail from the system, the patent reduces the number of components that need to be installed, positioned, and secured. This directly reduces installation labor costs while the remaining single rail is designed to maintain mounting reliability through optimized attachment points and spacing.
4Productivity
If a single row of rails is used for rows two and above, then the installation efficiency and cost effectiveness are improved, but the complexity of securing modules increases
Solution Approach 1:
The patent incorporates pre-designed attachment points, pre-spaced configurations, and pre-engineered clamp positions on the single rail. These preliminary design elements simplify the installation process by eliminating the need for complex field calculations and custom positioning, thereby maintaining high installation efficiency despite the reduced rail count.
Data Source
AI summary
A multi-rail system for mounting solar modules to a surface, such as a roof, uses two rails to support a first row of solar modules, and a single rail to support each subsequent row of solar modules. Splices connect edges of solar modules between rows, providing support along one edge of the solar modules for the subsequent rows.