Wedge Spring Clip PV Mounting for Rail-Free Module Installation
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Solution Overview
Problem
Traditional rail-based photovoltaic (PV) mounting systems require complex and time-consuming installations, use excessive materials, and increase installation costs due to the need for flashings that complicate the process and create potential leak points.
Innovation Solution
A rail-free PV mounting system utilizing a base portion with a spring clamp and clamping flanges that allows for tool-free and boltless installation, using a support beam to couple with the PV module frames without the need for additional fasteners, reducing material usage and installation time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional rail-based mounting systems are used, then structural stability is achieved, but installation time and complexity increase significantly
Solution Approach 1:
The patent removes the rail component from the mounting system, extracting only the essential function of supporting PV modules directly to the roof structure. This eliminates the complex rail assembly and disassembly processes while maintaining structural stability through direct roof-mounted brackets.
Solution Approach 2:
The mounting system is segmented into independent roof-mounted brackets that can be installed individually without requiring continuous rail structures. Each bracket functions independently to support PV modules, allowing for modular installation that reduces overall system complexity and installation time.
2Reliability
If traditional rail-based mounting systems are used, then structural stability is achieved, but material usage increases
Solution Approach 1:
The rail component is completely removed from the system, eliminating the substantial aluminum or steel rail materials that would otherwise be required. Only essential mounting brackets remain, significantly reducing material consumption while preserving the structural function of supporting PV modules.
3Object-affected harmful factors
If flashings are used in rail-free mounting systems, then water leakage protection is improved, but installation complexity and time increase
Solution Approach 1:
The flashing function is merged into an integrated design where the mounting bracket itself incorporates water protection features, or the flashing is pre-attached to the bracket as a single unit. This eliminates separate flashing installation steps and reduces overall installation time while maintaining water leakage protection.
4Object-affected harmful factors
If flashings are used in rail-free mounting systems, then water leakage protection is improved, but material costs increase
Solution Approach 1:
The flashing is combined with the mounting bracket into a single integrated component, eliminating the need for separate flashing materials and reducing overall material costs. The integrated design maintains water protection functionality while reducing the total quantity of materials required.
5Ease of manufacture
If existing roofing nails are removed to accommodate flashings, then proper flashing installation is achieved, but potential leak points increase
Solution Approach 1:
The mounting bracket is designed to accommodate existing roofing nails without requiring their removal. Pre-drilled holes or flexible mounting mechanisms are incorporated into the bracket design, allowing installation over existing nails while maintaining water protection and eliminating the creation of additional leak points.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The system significantly reduces installation time and costs by eliminating the need for flashings and tools, while maintaining the structural integrity and aesthetic benefits of rail-free solutions.
Implementation Method 1
A clamp having a spring base can be partially installed in the base portion. The support beam can be configured to forcibly fit between the clamping flanges of the clamp and resiliently deform the spring base to lock it into the base portion.
Data Source
AI summary
A photovoltaic (PV) mounting system having a base portion that is substantially planar and having a first roof-facing side and an opposite module-facing side. The base portion has a lip that circumscribes the perimeter of the base portion and curves inward on the module-facing side. A clamp having a spring base is partially installed in the base portion and has a pair of clamping flanges extending upwardly from the base portion. A support beam comprising a pair of ledges adapted to mate with the clamping flanges of the clamp and a bottom portion that is supported by the spring base. A PV module coupling device is mechanically coupled to the support beam and configured for coupling to the frames of at least two photovoltaic modules.