Solar Module Mount and Clamp Assembly for Faster Roof Installation
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Solution Overview
Problem
The existing process of mounting solar modules requires time-consuming identification and marking of mount assembly locations on an installation surface, which can be unsafe and inefficient.
Innovation Solution
A mount assembly and clamp system that allows securement to solar modules before they are positioned on the installation surface, enabling simultaneous lowering of modules and mounts onto the surface, thereby eliminating the need for pre-marking and enhancing safety by shifting labor-intensive tasks to the ground.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If mount assemblies are positioned and secured to the installation surface prior to solar modules being mounted, then the installation process requires time-consuming identification and marking of surface locations, but this ensures proper positioning and alignment
Solution Approach 1:
The mount assembly is pre-positioned on the solar module frame at the manufacturing stage, with positioning features such as rails and wings already attached. This preliminary action eliminates the need for time-consuming on-site identification and marking of installation locations, while ensuring precise positioning through factory-prepared alignment features
Solution Approach 2:
The mount assembly is divided into separable components including the rail, wings, and positioning features that can be independently manufactured and then assembled. This segmentation allows for precise manufacturing of individual components with positioning features, which are then easily attached to the solar module frame, maintaining positioning precision while reducing installation time
2Stability of the object's composition
If mount assemblies are secured to the installation surface before solar modules are mounted, then proper alignment is achieved, but the process becomes more complex and time-consuming
Solution Approach 1:
The mount assembly merges multiple functions into a single integrated unit that combines the mounting structure (rails and wings) with positioning features. This unified design attaches directly to the solar module frame, maintaining alignment stability through integrated positioning features while simplifying the installation process by eliminating separate positioning and mounting steps
Solution Approach 2:
The mount assembly incorporates self-positioning features such as rails and wings that automatically align with corresponding features on the solar module frame during installation. This self-service mechanism maintains alignment stability through built-in positioning geometry while reducing installation complexity by eliminating the need for external alignment tools or procedures
3Manufacturing precision
If mount assemblies are secured to the installation surface prior to module installation, then positioning accuracy is improved, but safety is reduced due to roof-level work requirements
Solution Approach 1:
The mount assembly is prepared in advance with all positioning features and mounting components attached to the solar module frame in a ground-level environment. This preliminary action transfers the precise positioning work from the hazardous roof environment to safe ground-level conditions, while maintaining positioning accuracy through factory-prepared alignment features
Solution Approach 2:
Instead of attaching the mount assembly to the installation surface first and then mounting the solar module, the invention inverts the sequence by pre-attaching the mount assembly to the solar module frame. This inversion moves the complex positioning work to ground level during manufacturing or pre-installation, eliminating the need for workers to perform precise positioning tasks at roof height
4Stability of the object's composition
If traditional mounting procedures are used with pre-positioned mount assemblies on the installation surface, then proper alignment is achieved, but labor intensity and time consumption increase
Solution Approach 1:
The mount assembly is pre-configured with all positioning features, rails, and wings attached to the solar module frame before delivery to the installation site. This preliminary preparation maintains alignment stability through factory-controlled positioning while dramatically improving productivity by eliminating on-site positioning and marking activities
Solution Approach 2:
The mount assembly is segmented into pre-manufactured components that are independently positioned and then quickly assembled to the solar module frame. This segmentation allows for precise manufacturing of individual positioning features while enabling rapid installation through simple assembly operations, thereby maintaining alignment stability while improving installation productivity
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
Accelerates the installation process and enhances safety by allowing securement of solar modules to the installation surface prior to lifting, reducing the time needed for marking and positioning, and ensuring safer handling of mount assemblies.
Implementation Method 1
a compressible seal with a circumferential pressure relief passageway
Data Source
AI summary
Mount and clamp assemblies employed in solar power installations are disclosed. In some embodiments, a mount assembly having a rail and opposing wings extending outwardly from the rail is disclosed. Each wing includes a top surface and a bottom surface for creating a chemical flashing, a groove and a sealant-receiving cavity extending away the bottom surface and upwardly into the wing, and a compressible seal with a circumferential pressure relief passageway. In some embodiments, a clamp having an upper member and a lower member with two horizontal flanges and a vertical flange is disclosed; in this embodiment, adjacent modules may be clamped together without an underlying structure mounted directly below to an installation surface. In another embodiment, a fourth flange is included in the mount assembly; in this embodiment, adjacent modules may be clamped together while being mounted directly to an installation surface.