Strut Runner Assembly for Low-Profile Rooftop Solar Mounting
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Solution Overview
Problem
The existing methods for mounting solar panels on rooftops are labor-intensive, costly, and aesthetically unpleasing due to the need for multiple stanchions that raise the equipment off the roof, requiring time-consuming and expensive processes for locating structural members, drilling, fastening, and sealing.
Innovation Solution
A strut runner system that allows direct mounting of solar module arrays to the underlying structure, reducing the need for stanchions by integrating with the roof decking, providing a waterproof solution, and lowering the overall height of the mounting assembly, while using fewer materials and less labor for installation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If stanchions are used to mount solar panels on rooftops, then the mounting process is reliable with proven sealing methods, but the installation becomes labor-intensive and time-consuming
Solution Approach 1:
The mounting system is divided into modular components: strut runners that attach to roof decking, and stanchions that attach to the strut runners. This segmentation allows pre-fabricated modules to be quickly installed while maintaining reliable sealing at each connection point, reducing overall installation time compared to traditional single-step stanchion mounting.
Solution Approach 2:
The strut runners are pre-installed and secured to the roof decking before the solar panel stanchions are attached. This preliminary action creates a prepared mounting surface that simplifies subsequent stanchion installation and ensures proper sealing positions are already established, improving installation efficiency.
2Strength
If traditional stanchion mounting is used, then structural support is adequate, but the aesthetic appeal deteriorates due to elevated equipment height
Solution Approach 1:
The strut runners extend horizontally along the roof surface, distributing the mounting function across a larger area. This dimensional approach allows the solar panels to be mounted lower to the roof surface while maintaining adequate structural support through the distributed strut runner system, improving aesthetic appearance without sacrificing strength.
3Reliability
If stanchions are used for mounting, then reliable weatherproofing can be achieved, but material costs and inventory requirements increase
Solution Approach 1:
The strut runner and flashing components are merged into an integrated assembly that provides both structural support and weatherproofing functions in a single unit. This consolidation reduces the total number of separate materials needed compared to traditional stanchion systems that require separate flashings, sealants, and mounting hardware, while maintaining reliable weatherproofing.
4Strength
If stanchion mounting process is used, then secure attachment is achieved, but installation complexity and labor requirements increase
Solution Approach 1:
The installation process is segmented into distinct phases: first installing strut runners to the roof decking, then attaching stanchions to the pre-installed runners. This segmentation simplifies each individual step compared to the traditional single-step process of directly mounting stanchions to the roof, reducing installation complexity while maintaining attachment security.
Data Source
AI summary
A strut runner includes a member extending lengthwise in a first direction, where the member includes an underlying panel and one or more walls that extend from the panel. The member may be configured to at least partially support the panel array while being integrated or directly connected to the underlying structure. Additionally, the strut runner may include one or more peripheral extensions that extend a distance outward from the body.