Variable-Geometry Fastener for Faster Solar Mount Installation
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Solution Overview
Problem
Conventional fasteners used in solar panel installations are limited by standard designs, which restrict installation speed and require significant manpower due to the need for multiple fasteners and adherence to published torque specifications.
Innovation Solution
The development of unconventional fasteners with variable minor diameters and thread depths, along with a greater thread pitch, allows for efficient installation by reducing the number of fasteners required and facilitating easier penetration into installation surfaces without the need for pilot holes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional fasteners with standard designs are used, then manufacturing commonality and reliability are improved, but installation speed and productivity deteriorate due to limited penetration capability and requirement for multiple fasteners
Solution Approach 1:
The patent applies parameter changes by modifying the fastener geometry parameters - specifically increasing the thread pitch and creating variable minor diameters along the shaft length. These parameter changes enable faster penetration into the substrate while maintaining secure fastening, thus improving installation speed without sacrificing reliability
Solution Approach 2:
The fastener shaft is segmented into different zones with varying minor diameters - a first portion with a first minor diameter and a second portion with a second minor diameter. This segmentation allows different sections of the fastener to perform different functions: one section optimized for penetration and another for secure anchoring, thereby improving both installation speed and reliability
2Reliability
If multiple fasteners are used to secure mounts, then fastening reliability is improved, but installation time and manpower requirements increase
Solution Approach 1:
The unconventional fastener is designed to perform multiple functions within a single component: it provides both rapid penetration into the substrate and secure long-term fastening. The variable geometry allows one fastener to replace what would traditionally require multiple fasteners, reducing installation time while maintaining mount fastening reliability
Solution Approach 2:
The patent merges the penetration function and the fastening function into a single integrated fastener design. By combining these functions that would traditionally require separate fasteners or multiple installation steps, the patent reduces installation time while maintaining the reliability needed for secure mount fastening
3Ease of manufacture
If conventional fasteners with constant minor diameters are used, then manufacturing simplicity is improved, but penetration efficiency and ease of operation deteriorate
Solution Approach 1:
The patent changes the geometric parameters of the fastener by implementing variable minor diameters along the shaft length and increased thread pitch. These parameter changes improve penetration efficiency and ease of operation while remaining compatible with standard manufacturing processes, thus maintaining ease of manufacture
4Productivity
If fasteners with greater thread pitch are used, then installation speed is improved, but thread engagement depth may be reduced
Solution Approach 1:
The patent applies parameter changes by increasing the thread pitch to improve installation speed. This parameter change is compensated by the variable minor diameter design, which ensures adequate thread engagement depth is maintained in critical sections, thereby preserving thread engagement strength while achieving faster installation
Data Source
AI summary
Fasteners along with systems and methods employing such fasteners for use of securing a surface component to an underlying wooden structure are disclosed. In some embodiments, a fastener has a minor diameter that is variable between proximal and distal ends of a shaft and a major diameter that is constant between the proximal and distal ends. In some embodiments, a fastener has a major diameter that is variable between the proximal and distal ends. In some embodiments, thread depth of the unconventional fastener having a greater thread depth than similarly-sized fasteners is disclosed. In some embodiments, a fastener has a thread pitch that is greater than a thread pitch of a similarly-sized published fastener.