Solar panel module mounting bracket
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional roof racking systems for solar panels face challenges in preventing water leakage through fastener attachment points, and the use of small, loose components during installation can be hazardous and inefficient.
Innovation Solution
A roof racking system comprising a bracket, a seal, and a flashing that work together to prevent water ingress through the fastener attachment point, using a bracket with an L-shape configuration and a flexible seal to secure the flashing, which is designed to minimize water permeation and reduce the risk of component loss during installation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If washers and seal elements are placed around the fastener to prevent water damage, then water protection is improved, but the device complexity increases
Solution Approach 1:
The patent combines the washer and seal elements into a single integrated mounting bracket assembly. The L-shaped bracket incorporates a seal element that directly contacts the roofing structure, eliminating the need for separate washers and seal components. This merging reduces the number of parts while maintaining water protection functionality.
Solution Approach 2:
The patent uses a flexible seal element made of elastomeric material that forms a thin film barrier around the fastener aperture. This flexible membrane conformally seals the penetration point, preventing water ingress through the mounting bracket hole without requiring complex rigid sealing structures.
2Ease of manufacture
If small, loose components are used in the racking system, then the ease of manufacture is improved, but the loss of time during installation increases due to component recovery
Solution Approach 1:
The patent merges multiple small loose components (bracket, washer, seal elements) into a single integrated mounting bracket assembly. This eliminates the need for installers to handle and recover multiple small parts during installation, reducing installation time while maintaining manufacturing simplicity through modular design.
Solution Approach 2:
The patent employs a nested structure where the seal element is positioned within a recess of the L-shaped bracket, and the fastener passes through both components in a nested arrangement. This nesting organizes multiple functional elements within a compact integrated unit, preventing loss and simplifying installation.
3Ease of operation
If conventional fasteners are used to attach the roof racking system, then the ease of operation is improved, but the object-affected harmful factors increase due to water leakage
Solution Approach 1:
The patent uses a flexible elastomeric seal element that conformally seals around the fastener where it penetrates the roofing structure. This flexible membrane adapts to the aperture shape and prevents water from entering through the fastener hole, protecting the roofing structure from water damage while maintaining easy installation.
Solution Approach 2:
The patent introduces a seal element as an intermediary component between the fastener and the roofing structure. This mediator prevents direct water contact with the penetration point, blocking the harmful water pathway while allowing the fastener to maintain its simple attachment function.
Data Source
AI summary
A seal includes an elongated body having a first end and a second end, an interior surface and an exterior surface, and a hole extending from the first end to the second end. The hole defines the interior surface of the body. The seal further includes a first flange disposed adjacent the hole on the first end of the body and a second flange disposed adjacent the hole on the second end of the body.