Photovoltaic Module Mounting Assembly With Interlocking Seam Brackets
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Solution Overview
Problem
Existing photovoltaic module mounting systems for standing seam metal panels often puncture the panels, leading to costly damage, leakage, and corrosion issues, and struggle to securely attach photovoltaic modules without compromising the integrity of the building surface.
Innovation Solution
A photovoltaic module mounting assembly comprising a mounting device, a lower bracket, an upper bracket, and a threaded clamp fastener, which attaches to the building surface without penetrating it, using a design that includes orthogonal legs and interlocking teeth to securely hold the module in place while avoiding damage to the panel.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a mounting assembly uses a bolt and clamping member to secure photovoltaic modules to standing seam panels, then the module attachment strength is improved, but the building surface is punctured causing leakage and corrosion issues
Solution Approach 1:
The patent introduces a mounting device with a slot that receives the standing seam panel as an intermediary mechanism. Instead of directly puncturing the panel, the slot engages with the panel's standing seam structure, allowing the mounting assembly to secure the photovoltaic module without creating puncture holes that would cause leakage and corrosion.
2Object-affected harmful factors
If a mounting device uses a slot to receive the standing seam panel, then the building surface integrity is preserved, but the attachment reliability may be compromised
Solution Approach 1:
The mounting device features a curved or arc-shaped slot that matches the contour of the standing seam panel. This curved geometry allows the slot to envelop and securely hold the panel profile, providing reliable attachment through geometric interlocking rather than mechanical fastening, thus maintaining both surface integrity and attachment reliability.
3Force
If the mounting assembly uses a threaded shaft and nut configuration, then the clamping force is increased, but the complexity of the device increases
Solution Approach 1:
The patent combines the threaded shaft and clamping member into a single integrated mounting device component. The threaded shaft is incorporated directly into the mounting device body, eliminating the need for separate clamping members and reducing the number of parts while maintaining the ability to generate sufficient clamping force through the threading mechanism.
Data Source
AI summary
A photovoltaic module mounting assembly (200) uses a mounting device (74), mounting plate (110′), lower bracket (210), upper bracket (230), and stud (114). The mounting plate (110′) is positioned on the mounting device (74), and a leg (212) of the lower bracket (210) is positioned on the mounting plate (110′). An outside surface (222) of another leg (220) of the lower bracket (210) includes teeth (224) and engages an inside surface (238) of a leg (236) of the upper bracket (230), which also has teeth (240). The mounting plate (110′) engages a lower surface (63) of a photovoltaic module (58), an end of the leg (212) of the lower bracket (210) may engage a side surface (64) of the module (58), and a head (246) on an end of another leg (232) of the upper bracket (230) may engage an upper surface (65) of the module (58).