Slate Tile Roof Clamp with Segmented Plates for Solar Mounting
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Solution Overview
Problem
The existing roof structure with solar cell modules is susceptible to rain leakage due to holes drilled in slate tiles and waterproof sheets, and is prone to loosening of mounting brackets if slate tiles crack, compromising both water tightness and mounting strength.
Innovation Solution
A roof structure with a fundamental roof base of overlapping slate tiles, each with attaching holes, using clamps with integrated lower and upper plates to secure fastening elements, ensuring that the attaching holes are covered by overlapping tiles to prevent water ingress and providing enhanced mounting stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If holes are drilled in slate tiles for mounting brackets, then mounting strength is improved, but water tightness deteriorates due to rain leakage through the holes
Solution Approach 1:
The clamp is divided into an upper plate and a lower plate that are separated by the slate tile. The lower plate is inserted between two slate tiles, while the upper plate is positioned on the exposed part of the slate tile. This segmentation allows the mounting holes to be distributed across different slate tiles, reducing the risk of water leakage through a single tile.
Solution Approach 2:
The lower plate is nested between two slate tiles (specific tile and underlying tile), while the upper plate is nested on the exposed part of the slate tile. The slate tile itself is nested within the clamp structure, creating multiple layers of protection against water leakage while maintaining mounting strength.
2Strength
If slate tiles are drilled for mounting brackets, then mounting strength is improved, but reliability deteriorates if slate tiles crack
Solution Approach 1:
The mounting system is segmented into upper and lower plates that work together. The lower plate is inserted between two slate tiles, providing alternative mounting paths. If one slate tile cracks, the other slate tile and the upper plate continue to provide mounting support, maintaining overall reliability.
Solution Approach 2:
The clamp structure is designed with built-in redundancy before any cracking occurs. The lower plate engages with both the specific slate tile and the underlying slate tile, creating multiple load paths. This prior cushioning ensures that if one tile fails, the mounting system continues to function.
3Strength
If mounting brackets are secured through multiple layers (boarding, slate tiles, waterproof sheet), then mounting strength is improved, but device complexity increases
Solution Approach 1:
The upper plate and lower plate are merged into a single clamp assembly that functions as one unit. The clamp combines the functions of securing to the slate tile and engaging with the solar cell module holder into a single integrated component, reducing the number of separate parts needed.
Solution Approach 2:
The clamp serves multiple functions: it provides mounting holes for securing to slate tiles, engages with the solar cell module holder, and distributes mounting loads across multiple slate tiles. This multi-functionality reduces the need for separate components for each function.
Data Source
AI summary
It is an object to develop a roof structure having a high capacity for water interception, being safe from leaking of rain, and ensuring a certain level of mounting strength even in breaking of one piece of roof members. Solar cell modules (10) are mounted on a fundamental roof structure (3) with slate tiles (roof member) (2) via eaves-side mounting brackets (eaves-side clamps) (5) and intermediate mounting brackets (clamps) (6). The intermediate mounting brackets (6) each are attached to an end portion of a specific roof member so that a lower plate (72) is positioned between the specific roof member and an underlying roof member. The lower plate (72) is fixed by a screw or the like driven in a hole (100). The specific roof member is arranged over the underlying roof member in which the screw is driven, thereby protecting an attaching hole (12) from rainwater seepage. An upper plate 73 overlaps the specific roof member with a fastening element (117, 118, 119) driven into the attaching hole (12). An overlying roof member is arranged over the specific roof member, thereby also protecting the attaching hole (12) from rainwater seepage.