Low-Profile Solar Panel Rail Mounting for Weather-Resistant Installation
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Solution Overview
Problem
Existing solar panel mounting systems face challenges in providing a structurally rigid, weather-resistant, easy-to-install, and aesthetically pleasing solution that is also low profile and inconspicuous, particularly when dealing with diverse surface materials and varying force vectors from weather elements.
Innovation Solution
A low profile mounting system featuring a rail with asymmetrically disposed opposing jaws forming a slot, a ledge for holding solar panel frames, a coupler for demountable connection, and a cleat for surface attachment, along with connectors to secure the system to the surface, allowing for secure and inconspicuous installation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional mounting systems are used to securely attach solar panels to surfaces, then structural rigidity and weather resistance are improved, but the visual profile becomes prominent and aesthetically displeasing
Solution Approach 1:
The mounting system transitions from a traditional above-surface mounting approach to a below-surface mounting approach. The rail is positioned beneath the solar panel, with only the necessary connection points visible at the panel edges, effectively moving the mounting structure to a different spatial dimension that preserves structural integrity while minimizing visual impact.
Solution Approach 2:
The mounting components are nested within the solar panel assembly structure. The rail is positioned within the panel frame structure, and connection elements are integrated into the panel edges, creating a compact nested arrangement that maintains strength while reducing the external profile.
2Reliability
If mounting systems are designed to be structurally rigid and weather-resistant, then reliability is improved, but installation complexity and difficulty increase
Solution Approach 1:
The mounting system is divided into separate modular components: the rail, the solar panel with integrated frame, and the mounting surface attachment elements. This segmentation allows each component to be manufactured and tested independently for weather resistance, while simplifying installation through modular assembly where components are pre-configured and require minimal on-site fabrication.
3Shape
If mounting systems are made low profile for aesthetic purposes, then visual appearance is improved, but structural strength and weather resistance may be compromised
Solution Approach 1:
The structural mounting elements are relocated to the reverse side of the solar panel assembly, beneath the visible surface. The rail is positioned below the panel front face, and connection points are located at the panel edges or rear, allowing the majority of the mounting structure to be hidden while maintaining full structural capacity through proper engineering of the concealed elements.
Data Source
AI summary
The specification and drawing figures describe and show a low profile mounting system that includes a at least one rail. A plurality of tracks is formed in the rail with opposing jaws. The opposing jaws define a slot. The opposing jaws are disposed in the rail asymmetrically to the longitudinal axis of the rail. At least one ledge monolithically extends from the rail for holding an object such as a solar panel. A coupler is provided for demountably connecting a solar panel to the rail. A cleat also is provided for attaching the system to a surface. A connector connects the rail to the cleat. This abstract is provided to comply with rules requiring an abstract that will allow a searcher or other reader to quickly ascertain the subject matter of the technical disclosure, but this abstract is not to be used to interpret or limit the scope or meaning of any claim.