Tile Replacement Solar Mounting System With Conical Post
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Solution Overview
Problem
Current solar panel mounting solutions for tile roofs are overly complicated, unreliable, and inadequate, requiring complex systems for secure installation.
Innovation Solution
A tile replacement solar panel frame mounting system that includes a base flashing, attachment bracket, and post with adjustable features such as chevron-shaped and curved ridge features, multiple attachment slots, and a conical protrusion to facilitate secure and water-resistant installation, allowing for easy adjustment and alignment without lifting adjacent tiles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If current solar panel mounting solutions are used on tile roofs, then solar panels can be mounted, but the system becomes overly complicated and difficult to install
Solution Approach 1:
The mounting system is divided into separate functional components: a base flashing that integrates with the tile roof, an attachment bracket that secures to the roof structure, and a post that connects to the solar panel frame. This segmentation allows each component to be optimized independently and simplifies installation by allowing sequential assembly without requiring complex integrated systems.
Solution Approach 2:
The invention extracts the mounting function from the tile roofing system itself, using a separate base flashing and attachment bracket system that works independently of the tile structure. This allows the solar mounting to be installed without modifying or removing tiles, eliminating the complexity of integrating mounting hardware directly into the tile roof.
2Reliability
If current mounting systems are used, then solar panels can be secured, but the system becomes unreliable and inadequate
Solution Approach 1:
The base flashing merges multiple functions into a single component: it provides water drainage, creates a sealed interface between the roof and mounting system, and serves as the foundation for the attachment bracket. This consolidation improves reliability by ensuring proper water management and structural support are integrated, while reducing the number of separate parts that could fail.
Solution Approach 2:
The base flashing is installed and sealed to the roof structure before the attachment bracket and post are assembled. This preliminary action ensures proper water drainage and sealing are established before the mounting hardware is put in place, preventing water intrusion issues that could compromise the reliability of the entire system.
3Strength
If complex mounting systems are used to secure solar panels to tile roofs, then attachment strength is improved, but water resistance is compromised
Solution Approach 1:
The base flashing provides localized water drainage and sealing specifically at the critical interface between the roof and mounting system. The attachment bracket provides localized structural attachment strength at the roof structure interface. By concentrating water protection and attachment functions at their respective optimal locations, the system achieves both strong attachment and effective water resistance without compromise.
4Productivity
If traditional mounting methods are used, then solar panels can be installed, but tile removal and reinstallation is required
Solution Approach 1:
The mounting system extracts the attachment function from the tile roofing material itself, using a base flashing that secures to the roof structure underneath the tiles. This allows the mounting hardware to be installed without removing or damaging the tiles, eliminating the time-consuming process of tile removal and reinstallation while maintaining roof integrity and water resistance.
Data Source
AI summary
A solar panel mounting system for use on flat and “S” tile roof structures includes a support arm coupled to a threaded post. A base flashing and corresponding attachment bracket are configured to couple with the post. A tile replacement flashing is installed over the base flashing and includes a conical protrusion with associated aperture. The aperture is configured to receive the post.