Rail-Less Solar Module Mounting With Waterproof Corner Coupling
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Solution Overview
Problem
Conventional photovoltaic (PV) module mounting systems require extensive materials, labor, and time for installation, often involving rails that increase costs, limit layout possibilities, and complicate waterproofing and grounding, making them inefficient and costly.
Innovation Solution
A rail-less roof mounting system that uses a base mount assembly with a clamp assembly for corner-to-corner coupling of PV modules, reducing material and labor needs, and providing a single grounding lug with elevated sealing for waterproofing, allowing for easy installation and adjustment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If conventional rail mounting structures are used to support PV modules, then structural stability is improved, but material usage and installation cost increase significantly
Solution Approach 1:
The patent removes the rail component from the mounting system entirely. Instead of using rails to support PV modules, the invention uses direct mounting brackets that attach to roof structures and hold modules individually or in pairs, eliminating the need for extensive rail material while maintaining structural stability.
Solution Approach 2:
The mounting system is divided into discrete, independent mounting points rather than continuous rails. Each mounting bracket can be independently installed and adjusted, allowing modular assembly that reduces overall material usage while maintaining the necessary structural support for each PV module.
2Reliability
If conventional rail mounting structures are used, then PV modules can be securely mounted, but installation time and labor cost increase
Solution Approach 1:
The mounting brackets incorporate adjustable and adaptable features that allow installers to quickly configure the system to different roof types and module orientations without requiring precise pre-engineering. This dynamic adaptability speeds up installation while maintaining secure mounting through field-adjustable mechanisms.
Solution Approach 2:
The mounting system is designed to be self-aligning and self-adjusting during installation, reducing the need for complex engineering calculations and precise measurements. The brackets can be easily positioned and secured by installers without requiring specialized engineering knowledge, thereby reducing installation time while ensuring reliable mounting.
3Strength
If rails are used for mounting PV modules, then structural support is provided, but waterproofing complexity and grounding requirements increase
Solution Approach 1:
By removing the rail system, the patent eliminates the complex network of penetrations and connections that rails create through the roof. The direct-mount bracket system requires fewer, simpler penetration points that are easier to waterproof and ground, reducing overall system complexity while maintaining necessary structural support.
4Ease of manufacture
If conventional mounting structures are used, then PV arrays can be installed, but shipping cost and design engineering time increase
Solution Approach 1:
The mounting brackets are designed as universal components that can be used across different roof types (shingle, metal, tile, flat) and module configurations without requiring custom-engineered solutions. This multi-functionality eliminates the need for extensive design engineering for each specific installation scenario, reducing engineering time while maintaining installation feasibility.
Solution Approach 2:
The mounting system allows for easy adjustment of key parameters such as mounting height, angle, and position during installation without requiring redesign or re-engineering. This flexibility enables adaptability to various site conditions and roof configurations while maintaining simple, standardized components that reduce both shipping costs and design engineering time.
Data Source
AI summary
A roof mounting system for the attachment of an article to a roof, the system comprising a plurality of PV modules each having at least one corner and a frame member, a flashing member having a top surface; an upstanding sleeve attached to the top surface of the flashing member; an elevated water seal having a borehole formed therethrough, the elevated water seal further comprising at least one screw for providing a waterproof seal between the article and the roof structure; and whereby the plurality of PV modules are interlocked in a way to provide a corner-to-corner coupling arrangement supported above the roof through the frame members of the plurality of PV modules.