Solar panel mounting apparatus
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Solution Overview
Problem
Current solar panel mounting systems lack the ability to easily adjust for varying module frame thicknesses, leading to installation challenges on non-uniform roof surfaces and requiring multiple mounting apparatuses for different frame heights.
Innovation Solution
A rail-less, indexable mounting assembly using stainless steel and aluminum alloys with a 'Click-On' tower attachment scheme, allowing for continuous height adjustment and accommodating a wide range of module frame thicknesses through a dovetail clamp and spring clip mechanism, enabling post-installation height adjustment and smooth panel alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a specific PV module mounting apparatus is selected based on PV module thickness, then the mounting apparatus can accommodate that specific thickness, but multiple different mounting apparatuses are required for different frame heights
Solution Approach 1:
The mounting apparatus uses a universal base plate with multiple vertically-spaced holes that can accommodate PV modules of various frame thicknesses (30mm to 50mm and beyond). The same base plate design serves multiple functions by allowing adjustment of the rail height to match different module thicknesses, eliminating the need for multiple specialized mounting apparatuses.
Solution Approach 2:
The mounting system incorporates adjustable components that allow the rail height to be dynamically changed relative to the base plate. This adjustability enables the same mounting apparatus to adapt to different PV module thicknesses, transforming a static mounting system into a dynamic one that can accommodate varying requirements.
2Ease of operation
If a fixed mounting apparatus is used for a specific frame height, then the installation is simple for that height, but adjustment for non-uniform roof surfaces and varying thicknesses is difficult
Solution Approach 1:
The base plate incorporates multiple vertically-spaced holes that allow the rail mounting position to be adjusted upward or downward. This dynamic adjustment capability enables installers to compensate for non-uniform roof surfaces and varying PV module thicknesses while maintaining a simple installation process using the same base plate design.
3Reliability
If multiple specialized mounting apparatuses are used for different frame heights, then each apparatus is optimized for its specific thickness, but inventory complexity and selection difficulty increase
Solution Approach 1:
Instead of maintaining multiple specialized mounting apparatuses optimized for different thicknesses, the invention uses a single universal base plate design with adjustable rail positioning. This universal design maintains reliability across different PV module thicknesses while dramatically simplifying inventory management and reducing the number of SKUs that need to be tracked.
Data Source
AI summary
A solar panel mounting assembly including a cap that includes a secure-side wing, a catch-side wing, and an integral vertical leg that protrudes downwardly from the catch-side wing. The vertical leg is integral with the catch-side wing and has a top end and a bottom end. A plurality of inwardly facing corrugations are disposed at the bottom end of the vertical leg. The solar panel mounting assembly further includes a base that includes a secure-side support surface, a tilted spring support ledge on a catch-side, and a plurality of outwardly-facing corrugations disposed on an upper horizontal portion of the base. An inwardly-facing corrugation of the vertical leg contacts and engages an outwardly-facing corrugation on the upper horizontal portion of the base, and the base is vertically adjustable with respect to the cap.