Support device for mounting a solar panel and mounting system incorporating same
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Solution Overview
Problem
Existing solar panel mounting systems on rooftops with sealing layers face challenges such as increased roof loading, water leakage risks, and high material and transportation costs, particularly when using ballast or penetrating fasteners, and require efficient and non-invasive attachment methods that withstand thermal expansion and wind forces.
Innovation Solution
A support device with a base and a panel mounting frame that uses flexible fastening members, such as straps, to securely attach to the rooftop without penetrating the sealing layer, utilizing ballast-receiving recesses for stabilization and allowing flexible fastening members to extend through the base for secure attachment, enabling secure mounting while maintaining the integrity of the rooftop membrane.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If weights or ballast are used to secure bearing rails on the rooftop, then the solar panel array can be stabilized against wind forces, but the loading on the roof structure substantially increases and may exceed design limits
Solution Approach 1:
The patent replaces the mechanical ballast system with a chemical bonding system. The bearing rails are secured to the rooftop through adhesive bonding or solvent bonding directly to the sealing layer, eliminating the need for weights or ballast. This substitution resolves the contradiction by providing stability through chemical adhesion rather than mechanical weight, thereby avoiding increased structural loading.
Solution Approach 2:
The patent introduces adhesive or solvent bonding as an intermediary substance between the bearing rails and the sealing layer. This intermediary creates a strong bond that secures the solar panel array without requiring additional weight, thus stabilizing the array while maintaining acceptable roof structure loading.
2Strength
If bolts and screw fasteners are used to secure bearing rails, then the rails can be firmly attached to withstand thermal expansion and wind forces, but the sealing layer is penetrated creating water leakage risks
Solution Approach 1:
The patent replaces the mechanical fastening system (bolts and screws) with a chemical bonding system. Adhesive or solvent bonding is used to attach the bearing rails to the sealing layer, eliminating penetration of the sealing layer. This substitution maintains attachment strength while preventing water leakage by preserving the integrity of the sealing layer.
Solution Approach 2:
The patent introduces adhesive or solvent bonding as an intermediary that creates a strong bond between the bearing rails and the sealing layer without penetrating the sealing layer. This intermediary substance provides the necessary attachment strength while maintaining the waterproof integrity of the sealing layer.
3Object-affected harmful factors
If adhesive bonding is used to secure bearing rails, then the sealing layer remains intact, but the bond durability may be insufficient to withstand thermal expansion and wind forces
Solution Approach 1:
The patent uses adhesive or solvent bonding as an intermediary substance that creates a durable bond between the bearing rails and the sealing layer. The bonding process is designed to withstand thermal expansion and wind forces while maintaining the integrity of the sealing layer, resolving the contradiction between bond durability and sealing layer protection.
Solution Approach 2:
The patent optimizes the bonding parameters including adhesive selection, application method, and curing conditions to achieve sufficient bond durability. By changing and optimizing these parameters, the bond strength is enhanced to withstand thermal expansion and wind forces while maintaining sealing layer integrity.
4Strength
If hot fusion or welding is used to secure bearing rails, then strong attachment is achieved, but the process is complex and may damage the sealing layer
Solution Approach 1:
The patent replaces the thermal processing system (hot fusion or welding) with a chemical bonding system using adhesive or solvent bonding. This substitution eliminates the complexity of heating equipment and thermal processes while achieving sufficient attachment strength. The chemical bonding process is simpler and less likely to damage the sealing layer compared to hot fusion or welding.
Data Source
Figure 1
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AI summary
The invention provides a solar panel mounting system (1) for mounting one or more solar panels (P), the system comprising: at least one support device (2) for supporting the solar panel (P) thereon, and at least one flexible fastening member (15). The support device (2) comprises: a base (3) adapted to seat stably on a substantially flat rooftop surface (R), the base (3) having at least one recess (5) for receiving ballast (B) to stabilise the support device (2) on the surface (R); and a mounting frame (9) upstanding from the base (3) and integral therewith, the mounting frame (9) being configured to support the solar panel (P) such that said panel (P) slopes downwardly towards a front edge region (6) of the base (3). The flexible fastening member (15) is adapted to engage and to extend from the support device (2), and has an attachment portion (17) which is adapted to be secured to a rooftop surface (R). Typically, a plurality of the support devices (2) are arranged spaced apart and essentially parallel to one another side-by-side in one or more rows for receiving and supporting a solar panel (P) extending between adjacent pairs of the support devices (2). Furthermore, a flexible fastening member (15) preferably engages and extends from each of the front and rear edge regions (6, 7) of each support device (2).