Mounting system and a method for mounting photovoltaic modules
11309830 · 2022-04-19
Assignee
Inventors
- Franz Neuhauser (Falkensee, DE)
- Heiko Molitor (Leipzig, DE)
- Henning Busse (Leipzig, DE)
- Marc Dewenter (Halle, DE)
- Thomas Ebenroth (Bitterfeld-Wolfen, DE)
- Thomas Linke (Oranienbaum-Woerlitz OT Kakau, DE)
Cpc classification
F24S25/632
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
Y02E10/50
GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
F24S2025/6007
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
Y02E10/47
GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
International classification
F24S25/632
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
Abstract
A mounting system for mounting a photovoltaic module onto at least one mounting rail. The mounting system comprises a frame for the photovoltaic module with at least one opening or protrusion at a lateral side or a bottom side of the frame, the bottom side being opposite to light incidence side of the photovoltaic module. The mounting system further comprises a plurality of mounting elements, each comprising a first portion and a second portion for securing the frame to the at least one mounting rail, the first portion defining a hook-like engagement portion to hook into the opening or the protrusion or the bottom side of the frame to provide an interlocking connection, the second portion enabling a secure fixation to the at least one mounting rail.
Claims
1. A mounting system for mounting a photovoltaic module onto at least one mounting rail, the system comprising: a frame for the photovoltaic module with at least one opening formed as a through hole through the frame at a bottom side of the frame, the bottom side being opposite to a light incidence side of the photovoltaic module, the at least one opening formed as the through hole having a closed and continuous perimeter, the frame having a protrusion that is a portion on the bottom side extending parallel to the light incidence side and comprising the at least one opening; and a plurality of mounting elements, each comprising a first portion and a second portion for securing the frame to the at least one mounting rail, the first portion defining a hook-like engagement portion to hook into the at least one opening to provide an interlocking connection, the second portion enabling a secure fixation to the at least one mounting rail; and wherein the first portion of at least one of the mounting elements comprises a plate shape with a cut-out part, the cut-out part being configured to receive the portion on the bottom side of the frame upon inserting the at least one of the mounting elements into the at least one opening of the frame and rotating the at least one of the mounting elements relative to the frame.
2. The mounting system according to claim 1, wherein the frame comprises a steel material and the second portion enables a screw connection between the mounting elements and the at least one mounting rail.
3. The mounting system according to claim 1, wherein a first portion of another of the at least one of the mounting elements is angled relative to a second portion of the another of the at least one of the mounting elements, and is formed plate-like to hook into another of the at least one opening formed as a slit at a lateral frame side.
4. A photovoltaic assembly comprising one or more photovoltaic modules; at least one mounting rails; and a mounting system according to claim 1 configured to mount the one or more photovoltaic modules onto the at least one mounting rail.
5. A method for mounting a photovoltaic module onto at least one mounting rail using a plurality of mounting elements, each comprising a first portion and a second portion, the method comprising: providing a frame for the photovoltaic module with at least one opening formed as a through hole through the frame at a lateral side or at a bottom side of the frame, the bottom side being opposite to a light incidence side of the photovoltaic module, and the at least one opening formed as the through hole having a closed and continuous perimeter, the frame having a protrusion that is a portion on the bottom side extending parallel to the light incidence side and comprising the at least one opening; hooking the first portion of one of the plurality of mounting elements into the at least one opening of the module frame to provide an interlocking connection, the first portion comprising a plate shape with a cut-out part configured to receive the portion on the bottom side of the frame upon insertion of the one of the plurality of mounting elements into the at least one opening of the frame, wherein hooking the first portion into the at least one opening includes rotating the one of the plurality of mounting elements relative to the frame; and fixing the second portion to the at least one mounting rail, thereby securing the frame to the at least one mounting rail.
6. The mounting system according to claim 1, wherein the at least one opening formed as the through hole through the frame defines a rectangular opening.
7. The method according to claim 5, wherein the at least one opening formed as the through hole through the frame defines a rectangular opening.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
(1) Various embodiments of the present invention will be described in the following by way of examples only, and with respect to the accompanying drawings, in which:
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DETAILED DESCRIPTION
(14) Various examples will now be described more fully with reference to the accompanying drawings in which some examples are illustrated.
(15) Accordingly, while examples are capable of various modifications and alternative forms, the illustrative examples in the figures will herein be described in detail. It should be understood, however, that there is no intent to limit examples to the particular forms disclosed, but on the contrary, examples are to cover all modifications, equivalents, and alternatives falling within the scope of the disclosure. Like numbers refer to like or similar elements throughout the description of the figures.
(16) It will be understood that when an element is referred to as being “connected” or “coupled” to another element, it can be directly connected or coupled to the other element or intervening elements may be present. In contrast, when an element is referred to as being “directly connected” or “directly coupled” to another element, there are no intervening elements present. Other words used to describe the relationship between elements should be interpreted in a like fashion (e.g., “between” versus “directly between,” “adjacent” versus “directly adjacent,” etc.).
(17) The terminology used herein is for the purpose of describing illustrative examples only and is not intended to be limiting. As used herein, the singular forms “a,” “an” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms “comprises,” “comprising,” “includes” and/or “including,” when used herein, specify the presence of stated features, steps, operations, elements and/or components, but do not preclude the presence or addition of one or more other features, steps, operations, elements, components and/or groups thereof.
(18) Unless otherwise defined, all terms (including technical and scientific terms) used herein have the same meaning as commonly understood by one of ordinary skill in the art to which examples belong. It will be further understood that terms, e.g., those defined in commonly used dictionaries, should be interpreted as having a meaning that is consistent with their meaning in the context of the relevant art and will not be interpreted in an idealized or overly formal sense unless expressly so defined herein.
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(20) The first portion 210 of the mounting element 20 is configured to secure the frame 10 to the at least one mounting rail and defines a hook-like engagement portion (the cut-out part 211) to hook into the opening 110 of the frame 10 to provide an interlocking connection. It may also be possible, that the cut-out part 211 receives the bottom side 15 that defines a protrusion capable to hold the frame 10. The second portion 220 with the through-hole 222 enables a secure fixation at the at least one mounting rail. The secure fixation may, for example, be done using a screw connection to the mounting rail.
(21) In the embodiment of
(22) When installing the photovoltaic modules on the rails at an installation site (e.g. a solar power plant), the mounting elements 20 are inserted in the openings 110 and subsequently rotated resulting in an interlocking connection between the mounting elements 20 and the frame 10 without the need of further mounting parts. The photovoltaic modules with inserted mounting element 20 can be handled as a unit and lifted from transportation means to place them on the mounting rails. The compound structure of photovoltaic module and mounting elements 20 will self-align on the mounting rails due to a mechanical stop provided by the inserted mounting elements 20. However, the photovoltaic modules are still movable horizontally along the rails and thus can be adjusted with respect to each other. To provide a permanent stable connection of the compound structure (photovoltaic module and mounting elements 20) with the rails, the mounting elements 20 may be secured to the rails using an exemplary screw connection or by using other permanent mounting means such as a clinch or a press joining, rivets, a welding or other. The connection may be established in a pre-strained way to compensate for any possible clearance or play between the mounting elements and the frame.
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(24) As mentioned above the bottom side 15 may likewise represent the projection 120 to allow the mounting elements 20 to hook into this portion. It is also possible that the projection 120 is formed as a loop 120b, for example in the plate-shaped bottom side 15.
(25) It will be appreciated that the depicted openings 110a, 110b, 110c and the protrusions 120a or 120b will generally not all be realized within a given frame 10. However, the various types of openings 110 or 120 may be implemented in various frames or at different sides of a frame according to embodiments of the present invention.
(26) The depicted frame 10 shows further a support portion 11 for the photovoltaic module. The photovoltaic module itself is not shown but can be inserted into the support portion 11 to hold the photovoltaic module, especially a solar module laminate. A solar module laminate comprises a solar cell string usually surrounded by an EVA (ethylene-vinyl acetate) foil and a glass on the light incidence (front) side and an EVA foil and a backsheet on the back side opposite to the light incidence side. The laminate and the frame together are commonly called a solar module.
(27) The frame 10 may further comprise a rectangular shape with a long and a short side. The short side of the frame 10 may hold the laminate by bent hold support portions (see
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(29) An exemplary screw connection 30 finally (tightly) secures the frame 10 to the mounting rail 6.
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(31) The frame 10 further comprises an optional slit-like opening 110a in the lateral frame side 13 to insert therein the upper of the folded parts 210 (the one which is not directly connected to the second portion 220). The through-hole 222 within the second portion 220 of the mounting element 20 is adapted to enable a screw connection 30 of second portion 220 to the mounting rail 6.
(32) The result is shown in
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(35) Optionally, the mounting element 20 comprises at least one locking mechanism 230 extending perpendicularly from the second portion 220. The locking mechanism is configured to prevent an inserted first part 210a in the loop opening 110c from being pulled out of the loop 110c. This locking mechanism may, for example, be a latch which provides a stop surface to latch the connection after the first part 210a has been inserted into the loop-like or slit-like opening 110c, 110a. Therefore, the mounting element 20 represents a snap-in mechanism that prevents a pullout of the mounting element 20.
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(38) The first mounting element 21 comprises two opposite wing portions 215a, 215b on opposite sides of the second portion 220 to mount the adjacent photovoltaic modules 4a, 4b onto one mounting rail 6. The second mounting element 22 comprises in addition to the second portion 220 sandwiched by two opposite wing portions 215a, 215b further bent edge portions 216a, 216b arranged on opposite sides of the second portion 220 and between the two wing-like portions 215a, 215b. The bent opposite edge portions 216a, 216b are configured to provide spacers between the adjacent photovoltaic modules 4a, 4b to define a predetermined clearance between the two photovoltaic modules 4a, 4b. The third mounting element 23 comprises no wing-like portions 215a, 215b, but instead further bent opposite edge portions 217a, 217b. Again, the bent edge portions 217a, 217b are configured to engage edge portions of the openings 110a, 110b to securely fix the frames 10a, 10b of the photovoltaic modules 4a, 4b to the one mounting rail 6.
(39) The depicted mounting elements 21, 22, 23 comprise a rectangular second portion 220, wherein on the edges of the rectangular second portion 220 either wing portions 215 or bent edge portions 216, 217 are formed.
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(43) This embodiment provides the advantage that the mounting element 20 can be pre-installed on the frame 10, for example at the lateral frame side 13 so that in the field, where the photovoltaic module shall be installed on the rail 6, the rotatable mounting element 20 can be rotated out of the frame 10. In addition, the frame 10 may comprise a stopper 108 which is configured to provide a stopping surface for the rotatable mounting element 20 so that the rotatable mounting element 20 can only be rotated out of the frame 10 up to a particular angle with which the photovoltaic module shall be installed on the underlying rail structure. The stopper 108 may, for example, be a punched out part from the lateral frame side 13. However, it is also possible to form a separate element on the frame 10 to provide such a stopper function. When the rotatable mounting element 20 is rotated out of the frame 10, the photovoltaic module can be placed on the rails 6 and does not need to be held by hand in order to fixate the frame 10 by the screw connection 30 to the rail 6.
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(45) As in the other embodiments, the second portion 220 is again secured to the rail 6 using an exemplary screw connection 30 passing through the through-hole 222.
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(47) Again, the depicted belt connection may also be used to mount a single frame 10 onto one rail 6.
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(49) Also for this embodiment the frame can simply be placed on the rail 6 without a person needed to hold the frame 10. The mounting element 20 provides sufficient support for holding the frame 10 (together with the laminate). The frame 10 can still be moved before the permanent fixation with the screw connection is made.
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(51) In other embodiments, two rows of solar modules can also be secured using only three rails, wherein, for example, the middle rail can be used to attach two neighboring solar modules onto this one middle rail. Examples for this fixation are shown in
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Embodiments of the present invention provide the following advantages: The photovoltaic modules 4 are installable independently from each other on mounting rail(s) 6 and can also be aligned on the mounting rails 6 independently. There is no manual holding needed, because inserted mounting elements 20 may provide a stop so that the modules 4 do not slide off the rail system 6, 8. The photovoltaic modules hold themselves via the mounting elements that, for example, can be attached to the frame of the photovoltaic module before placing the modules 4 on the rails 6. This simplifies the installation. It is possible to shift the photovoltaic modules horizontally during the installation along the mounting rails. The process of installation of a group of photovoltaic modules is simplified and needs less time. For example, it is possible to install the group of photovoltaic modules without any tools which results in a fast preparation in the field. The simple installation system allows the installation of many modules within a short time. The low degree of complexity allows several possibilities for the mounting elements. There is a simple access of the mounting elements, because embodiments are accessible from the rear side. Thus, additional improvements in respect to conventional systems relate to the post-processing or a replacement of already installed modules, because the mounting elements are independent of each other so that a single photovoltaic module can be replaced without disconnecting any adjacent photovoltaic modules. A disconnection of one photovoltaic module can be easily done. There is no or only a very little module-to-module gap or module-to-rail gap. Not much material is needed for the mounting system. In particular, no clamps or intermediate mounting elements are needed to mount the modules on the rails. The overall lifetime of the system can be increased, since the materials of all components can be the same so that a contact corrosion can be avoided. Embodiments of the present invention are more reliable when compared to conventional clamp connections. Since there is no protrusion on the front side (due to the fixation with mounting elements from the rear side), the front side is planar and closed without any gaps or protruding clamps, no accumulation of snow is possible. When compared to insertion systems, embodiments provide an increased load because the distance between adjacent support points is lower as well as the absent gap between the modules on the rails. In particular, the fluttering of insertion systems is not possible for the mounting system according to the present invention. Because of this, also the breaking of modules is less likely than for the insertion systems. In contrast to conventional clamp systems, embodiments enable to manufacture the rails from steel sheets. These steel sheets allow a cost-efficient manufacturing of the rail system. In addition, the direct mounting on the rails is less complex when compared to the clamp concepts, which need a groove in the rails. In addition, since also the frame of the photovoltaic modules can be made of steel, the contact corrosion as present in the conventional systems can be avoided since all materials can be made of steel. Moreover, steel is a material which allows thin wall thicknesses but nevertheless provides sufficient stability for the installed photovoltaic modules.
(53) The description and drawings merely illustrate the principles of the disclosure. It will thus be appreciated that those skilled in the art will be able to devise various arrangements that, although not explicitly described or shown herein, embody the principles of the disclosure and are included within its scope.
(54) Furthermore, while each embodiment may stand on its own as a separate example, it is to be noted that in other embodiments the defined features can be combined differently, i.e. a particular feature descripted in one embodiment may also be realized in other embodiments. Such combinations are covered by the disclosure herein unless it is stated that a specific combination is not intended.
LIST OF REFERENCE SIGNS
(55) 4 photovoltaic module(s) 6 mounting rail(s) 10 frame(s) 11 support portion for the photovoltaic module 12 bent portion of the frame 13 lateral frame side 15 bottom side of the frame 20, 21, 22, . . . mounting elements 30 screw connection 108 stopper 110 opening 120 projection 120a protrusion 120b loop 210 first portion of the mounting element 210a, 210b parts of the first portion 211 cutout part 212 gap 215 opposite wing-like portions 216, 217 opposite bent edge portions 218 clinch points 219 tongue element 220 second portion of the mounting element 222 through-hole 230 latch mechanism