Solar mounting assemblies
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Solution Overview
Problem
Current solar panel mounting solutions are complex, unreliable, and require multiple tools and sealants that degrade over time, making them difficult to level and install effectively.
Innovation Solution
A solar panel mounting system that uses a flashing with a cone-shaped protrusion and a single formed piece of metal, eliminating the need for sealants and incorporating internal features for alignment and moisture diversion, along with a support block and fastener system that allows for easy installation and leveling without tools.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If rubber seals are used to secure mounting to installation surface, then sealing function is provided, but reliability deteriorates due to degradation from thermal, UV, rain, and ice exposure
Solution Approach 1:
The patent removes rubber seals and sealants entirely from the mounting system. The flashing is designed to create a physical barrier and diversion system that eliminates the need for degradable sealing materials, directly addressing the reliability issue caused by sealant degradation.
Solution Approach 2:
The patent converts the harmful effect of water exposure by designing a flashing system with moisture diversion features that actively redirect water away from the mounting penetration points, transforming the potential harm of water intrusion into a controlled drainage system.
2Stability of the object's composition
If multiple penetration points are used to secure mounting, then structural stability is improved, but device complexity increases due to numerous penetration points and components
Solution Approach 1:
The patent combines multiple functions into a single integrated flashing component that provides both structural support and sealing functionality. The flashing integrates the mounting plate, seal, and drainage features into one piece, reducing the number of separate components and penetration points needed.
Solution Approach 2:
The flashing is designed as a multi-functional component that simultaneously provides structural attachment, weather sealing, and moisture diversion capabilities, eliminating the need for separate sealants, gaskets, and drainage components.
3Strength
If traditional mounting systems are used, then secure attachment is achieved, but ease of operation deteriorates due to difficulty in leveling and requirement for multiple tools
Solution Approach 1:
The flashing is pre-formed with integrated leveling features and attachment holes positioned to facilitate easy alignment and installation. The design incorporates built-in leveling lugs and pre-drilled holes that eliminate the need for complex measurement and adjustment during installation.
4Strength
If lag bolt with rubber seal is used, then mounting is secured to installation surface, but manufacturing precision deteriorates due to alignment difficulty and installation complexity
Solution Approach 1:
The flashing incorporates asymmetric features such as offset mounting holes and directional drainage channels that provide built-in alignment cues during installation, ensuring proper orientation and positioning without requiring complex measurement tools or procedures.
Data Source
AI summary
A structural support block cooperates with a cone-shaped protrusion in a roof flashing. The support block and protrusion have a through-hole allowing a fastener to secure the support block and flashing to a roof. Cooperation of the support block and the cone-shaped protrusion in the roof flashing diverts water, particularly on sloped surfaces.