Solar energy panel mounting structure
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Solution Overview
Problem
Rooftop solar energy systems face issues with roof penetrations leading to potential leaks due to friction between mounting components and the roof membrane, caused by vibrations and thermal expansion differences, which existing ballasted systems fail to adequately address.
Innovation Solution
An integrated sacrificial material is mechanically connected to the mounting structure, allowing for limited movement between the roof and the mounting components, reducing direct transmission of vibrations and thermal expansion effects, thus minimizing wear on the roof membrane. This material is pre-installed on the mounting structure and includes pins and flanges that allow the structure to slide freely while maintaining attachment, preventing direct contact that could cause leaks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a ballasted system with a metal tray is used to hold solar panels on the roof membrane, then the solar panel array is secured against wind load and building movements, but the friction between the tray and roof membrane during vibrations and thermal expansion causes wear holes and roof leaks
Solution Approach 1:
A sacrificial material layer is introduced as an intermediary between the metal ballasted mounting tray and the roof membrane. This sacrificial material absorbs the friction and wear that would otherwise directly affect the roof membrane, allowing the mounting structure to remain securely fixed while protecting the roof from damage during vibrations and thermal expansion cycles.
Solution Approach 2:
The sacrificial material is designed as a consumable, replaceable component that protects the permanent roof membrane. Over time, the sacrificial material wears down due to friction from building vibrations and thermal movement, but since it is replaceable and inexpensive compared to roof repair, it serves as an economical protective barrier that can be renewed without damaging the underlying roof structure.
2Stability of the object's composition
If the mounting structure is rigidly fixed to prevent movement, then stability is improved, but thermal expansion differences between the building and mounting system cause increased friction and wear on the roof membrane
Solution Approach 1:
The sacrificial material acts as a mediator that decouples the thermal expansion movements of the mounting structure from the roof membrane. The mounting structure can expand and contract freely relative to the roof without transmitting direct friction forces to the membrane, as the sacrificial material absorbs these movement differences.
Solution Approach 2:
The system changes the friction parameter at the interface between mounting structure and roof by introducing the sacrificial material. This material provides a controlled friction characteristic that allows for thermal movement while maintaining sufficient grip to prevent the mounting structure from sliding during wind loads and building vibrations.
3Adaptability or versatility
If separate installation of sacrificial material is required on-site, then customization and adaptability are improved, but installation time and complexity increase
Solution Approach 1:
The sacrificial material is pre-installed on the mounting structure during manufacturing before delivery to the installation site. This preliminary action eliminates the need for separate on-site installation of the sacrificial material layer, reducing installation time and complexity while maintaining the ability to customize different sacrificial material types for different roof conditions during the manufacturing stage.
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 significantly reduces wear on the roof membrane by allowing the mounting structure to move independently of the sacrificial material, thereby preventing leaks and extending the lifespan of the roof membrane.
Implementation Method 1
the ballast tray and other mounting components rub against the roof membrane during small building vibrations, small vibrations of the panels from wind, and differing thermal expansion rates between the building and solar energy mounting system
Implementation Method 2
Over time, this friction can wear a hole through the roof membrane and cause leakage into the building
Implementation Method 3
at least one flange is included to mate with the fastening end of the at least one mounting pin
Data Source
Figure 1~2
Figure 3
Figure 4
AI summary
A building rooftop mounting structure including a sacrificial material that allows freedom of movement between itself and the rooftop as well as between itself and the mounting structure.