Spring-Loaded PV Mounting Foot for Rail-Free Roof Installation
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Solution Overview
Problem
Existing rail-free PV mounting systems require complex installations, increase material costs, and slow down the installation process due to the need for flashings, which complicate site preparation and create potential leak points.
Innovation Solution
A PV module mounting system comprising a mounting puck with a clamp pin and arm portion that allows for tool-free installation, using a spring-loaded clamp pin to securely hold the arm portion against the puck, enabling boltless attachment to a structure and reducing installation time and material costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If traditional rail-based mounting systems are used, then structural stability is improved, but device complexity and installation time increase
Solution Approach 1:
The patent combines the mounting foot and clamp functions into a single integrated device. The L-shaped mounting foot integrates the vertical mounting component with the horizontal clamping arm, eliminating the need for separate rail structures and multiple clamps, thereby reducing system complexity while maintaining structural stability
Solution Approach 2:
The mounting foot serves multiple functions: it provides vertical support for mounting to the roof structure, horizontal clamping for securing the PV module frame, and structural connection between the roof and module. This multi-functionality replaces the need for separate rail and clamp components
2Stability of the object's composition
If traditional rail-based mounting systems are used, then structural stability is improved, but installation time increases
Solution Approach 1:
The mounting system is segmented into discrete, pre-fabricated mounting feet that can be independently installed and adjusted. Each mounting foot is a self-contained unit that can be quickly positioned and secured, allowing for faster installation compared to assembling complex rail structures on-site
Solution Approach 2:
The mounting feet are pre-fabricated with integrated clamping mechanisms and connection features before installation. The spring-loaded clamp pins are pre-assembled in the compressed state, ready for quick deployment during installation, eliminating the need for complex on-site assembly
3Reliability
If flashings are used to secure module supports to the roof, then water leak protection is improved, but installation complexity and time increase
Solution Approach 1:
The patent extracts the flashing requirement by designing mounting feet with integrated waterproofing features. The mounting foot itself incorporates the waterproof connection to the roof structure, eliminating the need for separate flashing components and their associated installation complexity
Solution Approach 2:
The mounting foot combines the structural mounting function with the waterproofing function into a single integrated component. The connection interface between the mounting foot and roof structure incorporates waterproofing features, eliminating the need for separate flashing layers
4Reliability
If flashings are used to secure module supports to the roof, then water leak protection is improved, but material costs increase
Solution Approach 1:
The patent removes the separate flashing material requirement by integrating waterproofing features directly into the mounting foot structure. This eliminates the need for additional flashing materials and their associated costs
Solution Approach 2:
The mounting foot merges the structural support function with the waterproofing function, using a single material component to achieve both objectives. This integration reduces the total material quantity required compared to using separate mounting and waterproofing components
5Reliability
If existing roofing nails are removed to accommodate flashings, then proper flashing installation is achieved, but potential leak points increase
Solution Approach 1:
The patent extracts the need to remove existing roofing nails by designing a mounting system that works with the existing roof structure. The mounting foot can be installed through or alongside existing fasteners without requiring their removal, eliminating the creation of new leak points
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The system significantly reduces installation time and material costs while maintaining the benefits of rail-free solutions, allowing for faster and more efficient solar panel installation with minimal disruption to roofing.
Implementation Method 1
A clamp pin can be formed in the mounting puck and adapted to restrain the arm portion against the mounting puck when a spring holding the clamp pin is released from a compressed position
Data Source
AI summary
A photovoltaic (PV) module mounting system including a mounting puck, an arm portion, and a PV module coupling device for coupling to the frames of two photovoltaic modules attached to the arm portion. A clamp pin formed in the mounting puck restrains the arm portion against the mounting puck when a spring holding the clamp pin is released from a compressed position.