Tabbed structural bracket
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Solution Overview
Problem
Existing solar mounting and racking systems require a large number of screws or fasteners to ensure structural integrity, which increases costs and labor due to the need for multiple bolts and nuts, and adds complexity in assembly.
Innovation Solution
A tabbed structural bracket with a mounting tab and hook that securely locks rotation, eliminating the need for additional fasteners by using an interference fit with pre-drilled apertures and through-holes, allowing for secure attachment to a mating beam without separate fasteners.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional brackets use multiple fasteners (bolts and nuts) to ensure structural integrity, then the connection strength is improved, but the device complexity and assembly time increase
Solution Approach 1:
The mounting tab combines multiple functions into a single integrated component: it provides structural support, enables attachment to the mating beam through the aperture, and locks rotation through its tab geometry. This eliminates the need for separate bolts and nuts, reducing assembly complexity while maintaining connection strength.
Solution Approach 2:
The mounting tab serves multiple purposes simultaneously: it acts as a structural support element, a mounting interface (through the aperture), and a rotation-locking mechanism (through its tab geometry). This multi-functionality reduces the number of separate components needed in the assembly.
2Reliability
If traditional brackets use multiple fasteners to secure the assembly, then the reliability of the connection is improved, but the quantity of materials and weight increase
Solution Approach 1:
The mounting tab integrates the functions of multiple fasteners into a single component. The tab's geometry provides both attachment (through the aperture) and rotation locking, eliminating the need for separate bolts and nuts while maintaining connection reliability.
Solution Approach 2:
The invention extracts and eliminates unnecessary fasteners (bolts and nuts) from the assembly by incorporating their functions directly into the mounting tab structure. Only essential fasteners remain, reducing the total quantity of materials while maintaining reliability.
3Strength
If traditional brackets require alignment of holes for fasteners, then the connection strength is improved, but the assembly time and labor increase
Solution Approach 1:
The mounting tab and hook are pre-configured in specific geometric orientations during manufacturing. This preliminary positioning eliminates the need for complex alignment operations during assembly, as the components are designed to fit together in a predetermined configuration, reducing assembly time while maintaining connection strength.
4Ease of manufacture
If the bracket uses a simple design with fewer components, then the manufacturing cost is reduced, but the ability to lock rotation may be compromised
Solution Approach 1:
The mounting tab combines structural support and rotation-locking functions into a single component. The tab's geometry is designed to engage with the mating beam in a way that prevents rotation, eliminating the need for separate locking mechanisms while maintaining manufacturing simplicity.
Solution Approach 2:
The mounting tab and hook are designed with asymmetric geometries that naturally prevent rotation when assembled. The tab extends in a specific direction and the hook engages at an angle, creating a configuration that is stable against rotational forces without requiring additional symmetric locking components.
Data Source
AI summary
A structural bracket for use with a solar mounting system is provided. The bracket has a first planar portion, and a second planar portion angularly positioned relative to the first planar portion, a mounting tab coupled to the second planer portion proximate a distal end of the second planer portion and a hook extending outwardly from the mounting tab at an angle, wherein the hook is configured to securely lock the structural bracket to a mating beam using an interference fit.