Solar Mounting Rail With Integrated Flanges for Direct U-Bolt Attachment
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Solution Overview
Problem
Prior art solar array support structures require additional costly angle iron components to attach mounting rails above horizontal rails, increasing construction and material costs.
Innovation Solution
A solar array support structure with a mounting rail featuring a dual web design, including a first and second vertical element, a solar panel mounting portion, and flanges with U-bolt holes spaced to match the width of horizontal rails, allowing direct attachment without additional angle irons using U-bolts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If angle iron components are used to attach mounting rails above horizontal rails, then the mounting structure is stable and reliable, but the material cost and construction cost increase significantly
Solution Approach 1:
The patent removes the angle iron component from the mounting structure, extracting the unnecessary intermediate element. The mounting rail is designed with integrated flanges that directly attach to horizontal rails using U-bolts, eliminating the need for angle irons while maintaining structural stability.
Solution Approach 2:
The patent combines the mounting rail and flange into a single integrated component. The flange is formed as part of the mounting rail structure, merging two previously separate elements (mounting rail and angle iron) into one unified component that reduces material usage and simplifies installation.
2Reliability
If angle iron components are used to attach mounting rails, then the mounting structure is stable, but the device complexity increases due to additional components and installation steps
Solution Approach 1:
The angle iron component is extracted and removed from the system. The mounting rail design incorporates flanges directly into its structure, eliminating the need for separate angle iron pieces and reducing the total number of components in the mounting assembly.
Solution Approach 2:
The mounting rail and flange are merged into a single integrated component. This consolidation reduces the number of parts that need to be handled, transported, and assembled, thereby simplifying the overall device complexity while maintaining mounting stability.
3Reliability
If angle iron components are used for mounting rail attachment, then the structure is stable, but the installation time and labor cost increase
Solution Approach 1:
The angle iron component is removed from the installation process. The mounting rail with integrated flanges can be directly attached to horizontal rails using U-bolts, eliminating the need for additional assembly steps involving angle irons and reducing overall installation time.
Solution Approach 2:
The flanges are pre-formed as part of the mounting rail structure during manufacturing. This preliminary action eliminates the need for on-site assembly of angle irons and reduces installation complexity, allowing for faster and more efficient mounting rail installation.
Data Source
AI summary
Disclosed herein is a mounting rail for a solar array support structure that includes a main body having a top and a bottom, the main body extending from a first end to a second end, the main body including a dual web having a first vertical element and a second vertical element. Further, the mounting rail includes a solar panel mounting portion extending along the top of the main body, the solar panel mounting portion configured to secure the solar panel to the mounting rail. Finally, the mounting rail includes a first flange extending from the bottom of the first vertical element, the first flange including a first pair of holes configured to receive two ends of a U-bolt, the first pair of holes spaced apart substantially equal to a width of a horizontal rail of a solar array support structure.