U.S. patent application number 13/979290 was filed with the patent office on 2014-02-13 for fastening system for mounting solar modules on a trapezoidal sheet.
This patent application is currently assigned to MOUNTING SYSTEMS GMBH. The applicant listed for this patent is Lisa Hertlein, Sandy Schnitzer. Invention is credited to Lisa Hertlein, Sandy Schnitzer.
Application Number | 20140041202 13/979290 |
Document ID | / |
Family ID | 45464610 |
Filed Date | 2014-02-13 |
United States Patent
Application |
20140041202 |
Kind Code |
A1 |
Schnitzer; Sandy ; et
al. |
February 13, 2014 |
Fastening System for Mounting Solar Modules on a Trapezoidal
Sheet
Abstract
A profile rail comprising in a cross-sectional view: a base
plate which forms a bottom side of the profile rail and which is
flat in sections or completely flat; a first and a second receiving
cavity for a rail support which cavities are both partially closed
laterally in outward direction and which respectively include a
lateral opening, wherein the two lateral openings are oriented in
opposite directions; and a third receiving cavity which includes an
opening that is oriented away from the bottom side of the profile
rail and which includes an inner profile for attaching module
attachment elements.
Inventors: |
Schnitzer; Sandy;
(Feldberger Seenlandschaft, DE) ; Hertlein; Lisa;
(Wildau, DE) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Schnitzer; Sandy
Hertlein; Lisa |
Feldberger Seenlandschaft
Wildau |
|
DE
DE |
|
|
Assignee: |
MOUNTING SYSTEMS GMBH
Rangsdorf
DE
|
Family ID: |
45464610 |
Appl. No.: |
13/979290 |
Filed: |
January 10, 2012 |
PCT Filed: |
January 10, 2012 |
PCT NO: |
PCT/EP2012/050296 |
371 Date: |
July 11, 2013 |
Current U.S.
Class: |
29/525.01 ;
403/188 |
Current CPC
Class: |
F24S 25/63 20180501;
Y10T 403/3906 20150115; Y02B 10/20 20130101; Y02E 10/47 20130101;
Y02B 10/10 20130101; F24S 25/615 20180501; F24S 2025/6002 20180501;
Y10T 29/49947 20150115; Y02E 10/50 20130101; F24S 25/35 20180501;
F24S 2025/801 20180501; F24S 2025/807 20180501; F24S 25/65
20180501; F24S 25/636 20180501 |
Class at
Publication: |
29/525.01 ;
403/188 |
International
Class: |
F24J 2/52 20060101
F24J002/52 |
Foreign Application Data
Date |
Code |
Application Number |
Jan 12, 2011 |
DE |
10 2011 002 601.0 |
Oct 14, 2011 |
DE |
10 2011 084 556.9 |
Claims
1. A profile rail comprising in a cross-sectional view: a base
plate which forms a bottom side of the profile rail and which is
flat in sections or completely flat; a first and a second receiving
cavity for rail supports which are both partially closed laterally
in an outward direction and which respectively include a lateral
opening, wherein the two lateral openings are oriented in opposite
directions; and a third receiving cavity which includes an opening
that is oriented away from the bottom side of the profile rail and
which includes an inner profile for attaching module attachment
elements.
2. The profile rail according to claim 1, wherein the first or the
second receiving cavity is internally defined by a C-shape.
3. The profile rail according to claim 1, wherein the first
receiving cavity or the second receiving cavity is laterally closed
partially in outward direction by at least one lateral bar arranged
orthogonal to the base plate.
4. The profile rail according to claim 1, wherein the second
receiving cavity is mirror symmetrical to the first receiving
cavity with respect to an imaginary center plane which is
orthogonal to the base plate.
5. The profile rail according to claim 1, wherein the inner profile
includes cranks at different walls or bars, wherein the cranks
extend substantially parallel to the base plate, wherein a first
crank has a greater distance from the base plate than a second
crank, and wherein the inner profile further includes a first and a
second contact surface for an attachment element whose distances
from the base plate are smaller than a distance of the first crank
from the base plate.
6. The profile rail according to claim 1, wherein the first contact
surface and the second contact surface are parallel to the base
plate.
7. The profile rail according to claim 5, wherein the first crank
and the first contact surface overlap at least partially, or
wherein the second crank and the second contact surface overlap at
least partially.
8. The profile rail according to claim 5, wherein the inner profile
includes a bar that protrudes from a plane of the base plate,
wherein the bar is arranged between two inner walls of the profile
rail that are arranged opposite to one another, wherein the bar has
a second crank at its end that is remote from the base plate, and
wherein the first crank is arranged at a first inner wall and
oriented in the same direction as the second crank.
9. The profile rail according to claim 8, wherein the bar is
orthogonal to the base plate.
10. The profile rail according to claim 8, wherein the first
contact surface protrudes from the first inner wall.
11. The profile rail according to claim 8, wherein the second
contact surface is arranged at the end of the bar that is remote
from the base plate.
12. An attachment system for mounting solar modules on a
trapezoidal sheet which includes raised beads and associated
flanks, comprising at least one profile rail according to claim 1;
and a plurality of rail supports respectively including a main
element, a first clearance hole through the main element, and a
T-shaped component extending from the main element, wherein the
profile rail is attachable at the raised beads via the rail
supports, wherein the T-shaped components engage the lateral
openings respectively of the first or the second receiving cavity
and with attachment of the rail supports at the flanks via
attachment devices through clearance holes, wherein the top sides
of the main elements of the rail supports do not protrude beyond a
top side of the profile rail in assembled condition.
13. An arrangement for attaching solar modules with an attaching
system according to claim 12 and a trapezoidal sheet which includes
raised beads and associated flanks, wherein the profile rail rests
on the raised beads, wherein the rail supports are attached with
attachment devices through their clearance holes at the flanks of
the raised beads of the trapezoidal sheet, and wherein the T-shaped
components of the rail supports either engage a respective lateral
opening of the first or the second receiving cavity of the profile
rail.
14. A method for mounting an attachment system according to claim
12 on a trapezoidal sheet which includes raised beads and
associated flanks, the method comprising the steps: a) placing the
profile rail with its bottom side on raised beads of the
trapezoidal sheet; b) inserting the T-shaped element of one of the
rail supports into one of the receiving cavities of the profile
rail; c) attaching the rail support at one of the flanks with an
attachment device which extends through a clearance hole of the
rail support; d) repeating steps b) and c) at least once with
respectively one further rail support.
15. A method according to claim 14, wherein the rail supports are
mounted on both sides of the profile rail.
Description
[0001] The invention relates to a profile rail, an attachment
system for mounting solar modules on a trapezoidal sheet, an
arrangement for attaching solar modules on a trapezoidal sheet and
a method for mounting an attachment system according to the
invention on a trapezoidal sheet.
[0002] Solar modules, for example photovoltaic modules for
generating electrical energy or collector modules for heating heat
transfer media are typically attached in roof or ground assemblies
on profile rails that are arranged parallel to one another.
[0003] Trapezoidal sheets are typically used for roofs of
industrial and commercial buildings, since the trapezoidal sheets
are much stronger than flat metal plates due to their shape.
Trapezoidal sheets include raised beads and adjacent flanks in a
continuous metal plate, wherein the adjacent flanks protrude from
beads of the trapezoidal sheet.
[0004] Known attachment systems provide an attachment of the
profile rail on the raised beads of the trapezoidal sheet. For this
attachment type, there is a risk that screws or rivets are torn out
under strong wind loads due to material thickness typically
starting at 0.5 mm.
[0005] A known attachment system for mounting solar modules on a
trapezoidal sheet is being offered under the trade name
VarioFix-V-System by Schletter GmbH. There a profile rail is being
used which has a C-shaped inner profile at a bottom side. For
mounting purposes, supports with a rectangular main element and a
T-shaped component are being used, wherein the T-shaped component
protrudes from a center of a long side of the rectangle and in the
same plane. The supports are inserted into the C-shaped profile
with the respective T-shaped components and attached with
attachment devices like screws or rivets at two clearance holes at
flanks of the trapezoidal sheet. Thus, the supports are entirely
below the profile rail. Mounting a system of this type is
cumbersome since the supports have to be inserted from below into
the already contacting profile rail.
[0006] It is desirable to be able to mount solar modules on a
trapezoidal sheet in a simpler manner.
[0007] A first aspect of the present invention relates to a profile
rail comprising in a cross-sectional view: [0008] a base plate
which forms a bottom side of the profile rail which is flat in
sections or completely flat, [0009] a first and a second receiving
cavity for rail supports which are both partially closed laterally
in outward direction and which respectively include a lateral
opening, wherein the two lateral openings are oriented in opposite
directions, and [0010] a third receiving cavity which includes an
opening that is oriented away from the bottom side of the profile
rail and includes an inner profile for attaching module attachment
elements.
[0011] The profile rail according to the invention facilitates
particularly simple mounting of an attachment system for solar
modules on a trapezoidal sheet. Rail supports can be mounted at
sides of the profile rail on flanks of the raised beads of the
trapezoidal sheet and can be connected with the profile rail in
both receiving cavities provided for this purpose. The profile rail
furthermore facilitates an attachment at the trapezoidal sheet,
which allows expansions or contractions caused by temperature
changes.
[0012] Based on the described features the profile rail can be
mounted in a simple manner so that rail supports which can
laterally engage the receiving cavities provided for this purpose
contact flanks of the raised beads of the trapezoidal sheet and are
connected with an attachment device like a screw or a rivet at the
respective flank. The load of the trapezoidal sheet is thus
performed through shearing, which facilitates introducing much
higher forces into the trapezoidal sheet so that higher loads can
be supported compared to the profile rail only being screwed down
from above and the trapezoidal sheet only being loaded through
tension.
[0013] The support is preferably attached at the flanks of the
raised beads so that it is only arranged in an upper third of the
flank, for example when typical trapezoidal sheets are used. Thus,
a penetration directly in the water conducting bead is
prevented.
[0014] The profile rail according to the present invention also
facilitates a use on different profile geometries of trapezoidal
sheets. This is important for variable use of the profile rail due
to the plurality of embodiments of trapezoidal sheets.
[0015] The first and the second receiver cavity for rail supports
are both partially closed in a respective lateral outward
direction. Accordingly, the receiver cavities have a respective
lateral opening towards the ambient of the profile rail. Lateral
directions in the context of the instant application are directions
transversal to the longitudinal rail orientation, which are not
simultaneously perpendicular to the base plate.
[0016] Subsequently, embodiments of the profile rail are
described.
[0017] The base plate of the profile rail preferably has a
completely flat bottom side. This facilitates even contact on
raised beads of a trapezoidal sheet. The base plate, however, can
also be flat in sections, for example when a notch in the base
plate shall be configured for fabrication and transportation
reasons or when the notch in the base plate shall be used for
fixating the profile rail. The bottom side of the base plate also
defines a bottom side of the profile rail.
[0018] The receiving cavities for rail supports are defined in one
embodiment C-shaped on an inside. Put differently, the inner
defining bars of the rail supports form a C-shape in
cross-sectional view. A C-shaped delimitation of this type can be
facilitated in a suitable manner by three arms from which two arms
are also oriented horizontally and one is oriented vertically
relative to a horizontally extending base plate. When these arms
are arranged at a right angle relative to one another, this yields
a particularly simple, compact and stable embodiment.
[0019] The C-shape that is partially closed in outward direction
facilitates using rail supports with a T-profile that engages in a
complementary manner. Rail supports of this type facilitate a
particularly stable and well adjustable attachment through lateral
engagement in the openings of the receiver cavities as will be
described infra in more detail.
[0020] Alternatively, the C-shaped delimitation of a first or
second receiving cavity can also be configured by arms that are at
different angles to each other than right angles, or it can be
configured arcuate. Also in these cases, at least portions of the
C-shaped delimitation can be associated with the typical elements
of the letter C in its simplest representation, at least mentally,
wherein the simplest representation of the letter C includes two
horizontal beams and a vertical beam. In different embodiments of a
C-shaped delimitation, it is also feasible that the transitions
between respective sections which can be associated with the
respective bars of the letter C are continuous.
[0021] Defining the opening of the receiver cavities for rail
supports can be provided for example through lateral bars.
[0022] In one of two alternative embodiments, a single lateral bar
is being used. A particularly simple embodiment is facilitated when
a lateral bar is arranged on the base plate perpendicular to the
base plate. A lateral bar of this type facilitates that a for
example U-shaped connection device establishes a form-locking
connection therewith and exerts s a force which presses the bottom
side of the respective profile rail onto the base formed by the
respective trapezoidal sheet. A force of this type can support the
profile rail on the base. Furthermore, the form-locking connection
can prevent a lateral slide off of the profile rail.
[0023] In one variant of the first alternative embodiment, only an
upper lateral bar is used for partially closing the receiving
cavity for rail supports in laterally outward direction. A
receiving cavity thus configured can form a form locking connection
with an S-shaped connection device of a rail support and can
support the profile rail on the base in this manner and can secure
it against slide off and tilting. Preferably the upper lateral bar
is arranged perpendicular to the base plate.
[0024] Preferably the definition of the opening of the receiving
cavity for rail supports is formed in the other of the two
alternative embodiments by a lower side bar and by an upper side
bar as they were described infra in a context with the variants of
the first alternative, wherein the side bars of a respective
receiver cavity are respectively arranged orthogonal onto the base
plate and are arranged in alignment with one another. This
implements an embodiment with a particularly simple configuration
which is also particularly compact with respect to its external
dimension. Furthermore, stabilization in longitudinal direction is
realized through a combination of elements of the profile rail that
are oriented perpendicular relative to one another. The embodiment
with an upper and a lower transversal bar at the opening of the
receiving cavity for rail supports otherwise has the advantage of
particular suitability to receive a T-shaped connection device of a
rail support and to form a form-locking connection therewith. Thus,
a beam of the T-shaped connection device comes into engagement with
the lower and also with the upper side bar. This stabilizes the
profile rail additionally and thus in particular against
tilting.
[0025] The respective lateral openings of the receiving cavities of
a profile rail according to the first aspect of the invention are
oriented in opposite directions. Opposite directions are directions
which differ by more than 90.degree.. Particularly preferably they
differ by more than 120.degree. and additionally preferably, they
differ by approximately or exactly 180.degree.. This facilitates
that the openings are configured to insert T-shaped elements of
rail supports respectively laterally relative to the profile rail.
The direction in which an opening of the receiver cavity is
oriented is perpendicular to a surface between the ends of the
elements defining it, for example the lateral bars and is oriented
away from the receiving cavity with respect to this surface.
[0026] According to a particularly preferred embodiment, the second
receiving cavity is configured mirror-inverted relative to the
first receiving cavity with respect to an imaginary central plane
that is perpendicular to the base plate. This facilitates a
particularly simple and compact embodiment of the profile rail.
[0027] The lateral openings of the first and second receiving
cavity do not have to be the only openings of these receiving
cavities. Rather, also additional openings, for example for
draining rain water, can be provided.
[0028] Depending on the arrangement of the third receiving cavity,
the configuration of the profile rail in lateral direction can be
provided narrower or wider.
[0029] The third receiving cavity can be configured between the
first and the second receiving cavity for rail supports which
facilitates a wider configuration for the profile rail.
Alternatively, the third receiving cavity can also be configured
above the first and the second receiving cavities. This facilitates
a narrower embodiment of the profile rail in which the first and
the second receiving cavities can be arranged closely adjacent to
one another. By the same token it is also feasible that the third
receiving cavity is only configured partially above and partially
between the first and the second receiving cavities. This
facilitates for example providing stabilizing structures below the
third receiving cavity.
[0030] The third receiving cavity includes an inner profile which
is used for attaching module attaching elements. Module attaching
elements are generally defined as elements which are used for
establishing a fixed connection between the profile rail and a
solar module.
[0031] The inner profile can be configured in different ways. For
example, two opposite bars can be arranged at the side of the third
receiving medium opposite to the base plate, which facilitate that
a T-shaped element or a slot nut forms a form-locking connection
therewith. An embodiment of this type can correspond to an
embodiment of the first or second receiving cavity with an upper
and lower side bar as described supra rotated by 90 degrees. The
invention, however, is not limited to this embodiment; rather, any
inner profile can be used which facilitates attaching components on
the profile rail, for example solar modules. Additional preferred
embodiments are described infra.
[0032] According to a preferred embodiment, the inner profile
includes cranks at different walls or bars, wherein the cranks
extend substantially parallel to the base plate, wherein a first
crank has a greater distance from the base plate than a second
crank and wherein the inner profile further includes a first and a
second contact surface for an attachment element whose distances to
the base plate are smaller than the distance of the first base
plate. In an embodiment of this type, it is facilitated through
arrangements of the two cranks at a different distance to the base
plate that first and second engagement surfaces which are provided
in assembled condition for engagement with the first and second
crank do not have to be arranged in one plane for an arrangement
with one connecting block which shall be used for attaching solar
modules on the profile rail. This facilitates particularly simple
insertion of the connecting block in the profile rail through slide
tilting. The first and the second contact surfaces facilitate that
the connecting block remains in place on those two contact surfaces
after inserting and that the connecting block is secured against
fallout, wedging and rotation. Thus a series of sliding blocks can
be inserted into the respective profile rail during assembly before
the sliding blocks are subsequently used for attaching solar
modules. Since the connecting block shall initially contact the
first contact surface and the second contact surface and shall be
subsequently pressed upward by an upward oriented force against the
two cranks, it is required that the distances of the first and
second contact surfaces to the base plate are smaller than at least
the distance of the first of the two cranks from the base
plate.
[0033] Preferably, the first contact surface and the second contact
surface are parallel to the base plate. Furthermore, the first
contact surface and the second contact surface are arranged at the
same distance from the base plate. Applying a connecting block with
a flat bottom side is thus facilitated.
[0034] According to one embodiment, the first crank and the second
contact surface overlap at least partially. According to an
additional embodiment, the second crank and the second contact
surface overlap at least partially. Those two embodiments can
certainly also be combined with one another.
[0035] According to a particularly preferred embodiment, the inner
profile includes a bar extending from a plane of the base plate,
wherein the bar is arranged between two inner walls of the profile
rail that are arranged opposite to one another and wherein the bar
includes the second crank at its end that is remote from the base
plate. Furthermore the first crank is arranged at a first inner
wall and is oriented in the same direction as the second crank.
Through this embodiment of the inner profile, using a connecting
block with U-shape is facilitated. Thus the connecting block can
include a first engagement surface which comes into engagement with
the first crank under an impact of an upward oriented force and the
first connecting block can furthermore include a second engagement
surface which comes into engagement under an effect of upward
oriented force with the second crank. The second engagement surface
of the connecting block is then arranged at a top side of a
respective other arm of the U that differs from the arm on which
the first engagement surface is arranged.
[0036] Preferably, the bar is arranged perpendicular to the base
plate. This facilitates a particularly simple embodiment that
stabilizes in longitudinal direction.
[0037] In a preferred embodiment, the first contact surface extends
from the first inner wall. Thus, the first crank and the first
contact surface overlap at least partially. The clearance of the
connecting block after insertion and before attachment is therefore
limited on both sides at the first inner wall.
[0038] According to another preferred embodiment, the second
contact surface is arranged at an end of the bar that is remote
from the base plate. Thus the bar does not only have the function
to support the second crank at the desired position, but
simultaneously also forms the second contact surface. An additional
element for providing the second contact surface can thus be
avoided. In particular in this embodiment it is particularly
advantageous when the first and second contact surfaces have the
same distance from the base plate, thus namely a level and flat
application of a connecting block with a flat contact surface is
facilitated.
[0039] According to an alternative embodiment, the inner profile is
configured so that a simple slot nut can be inserted and attached.
According to another alternative embodiment, the inner profile is
configured so that a hexagonal nut can be laterally inserted and
attached.
[0040] A second aspect of the invention relates to an attachment
system for mounting solar modules on a trapezoidal sheet which
includes raised beads and associated flanks including at least one
profile rail according to the first aspect of the invention and a
plurality of rail supports respectively including the following:
[0041] a main element, [0042] a first clearance hole in the main
element, and [0043] a T-shaped component extending from the main
element,
[0044] wherein the profile rail is attachable at the raised beads
via the rail supports, wherein the T-shaped components engage the
lateral openings respectively of the first or the second receiving
cavity with attachment of the rail supports at the flanks via
attachment devices through the clearance holes,
[0045] wherein the top sides of the main elements of the rail
supports do not protrude beyond a top side of the profile rail in
assembled condition.
[0046] An attachment system of this type includes an inventive
combination of a profile rail with associated rail supports. The
supports can be easily brought into a form locking connection with
the profile rail through the T-shaped component extending from the
main element. Thus the T-shaped component is either inserted into
the first or into the second receiving cavity for the rail support
of the profile rail and rotated in a suitable manner. Furthermore,
the supports can be attached through their respective clearance
holes at a respective flank of a trapezoidal sheet. Thus the main
element which is freely movable in longitudinal direction and which
can still be rotated further after insertion of the T-shaped
component into one of the two lateral openings of the profile rail
and after rotating the T-shaped component in the respective first
or second receiving cavity for rail supports is preferably placed
flat onto a flank of the trapezoidal sheet. For attachment
purposes, typical elements like screws or rivets are suitable which
are inserted through the clearance hole and driven into the
material of the trapezoidal sheet. Thus a fixated and non-movable
connection between the support and the trapezoidal sheet can be
configured. Thus as described supra, the profile rail can be
fixated on the trapezoidal sheet and secured against sliding off or
tilting through a fixated connection of this type through form
locking connection of the support at the profile rail.
[0047] It is appreciated that the top sides of the rail supports of
the attachment system do not extend according to the invention in
assembled condition beyond a top side of the profile rail. This
facilitates lateral assembly of the rail supports at the profile
rail and flat placement of a solar module on the profile rail.
[0048] A third aspect of the invention relates to an arrangement
for attaching solar modules with an attaching system according to
the second aspect and a trapezoidal sheet which includes raised
beads and associated flanks, [0049] wherein the profile rail rests
on the raised beads, [0050] wherein the rail supports are attached
with attachment devices through their clearance holes at the flanks
of the raised beads of the trapezoidal sheet, and [0051] wherein
the T-shaped components of the rail supports either engage the
lateral opening of the first or the second receiving cavity of the
profile rail.
[0052] The arrangement according to the third aspect of the
invention thus relates to a combination of a trapezoidal sheet with
an attachment system according to the second aspect in assembled
condition. As described already in conjunction with the attachment
system, the main elements of the rail supports preferably rests
plane on the respective flanks of the trapezoidal sheet in contact
surfaces and form a form locking connection with the profile rail
through their T-shaped components. Thus the rail supports are
arranged on sides of the profile rail. Thus the profile rail is
fixated on the raised beads of the trapezoidal sheet. Thus the
trapezoidal sheet and the profile rail form a permanently connected
unit.
[0053] Preferably flat spacers are installed between the
trapezoidal sheet and the profile rail. These spacers can be
produced for example from ethylene propylene diene monomer rubber
(EPDM) which has properties that are advantageous for this type of
application. The spacers help to prevent contact corrosion between
the materials.
[0054] As already indicated, in conjunction with the profile rail
according to the invention, the arrangement according to this
aspect of the invention is characterized in that rather large
forces can be introduced into the trapezoidal sheet and thus higher
loads can be sustained (shear loading). The support of the profile
rail according to the invention facilitates tolerance relative to
temperature based length changes of the materials.
[0055] When mounting the supports, the arrangement according to the
invention facilitates particularly high flexibility. The number of
the supports can be reduced further based on the static loads. The
supports can be mounted at the flanks of each raised bead but they
can for example also be mounted at every second or third raised
bead. Thus not only the loading of the trapezoidal sheet can be
optimized as recited supra.
[0056] According to one embodiment of the arrangement, the rail
supports of a respective profile rail are accordingly only mounted
on one side of the profile rail. This means that either in the
first or the second receiving cavity for the rail support, no rail
support is attached. Based on the configuration of the receiving
cavity and of the rail supports, this can suffice in principle for
safe assembly of the profile rail.
[0057] Preferably, however, the rail supports are mounted on both
sides of the profile rail, so that a respective support effect
occurs on both sides of the profile rail. This yields a
particularly advantageous distribution of the forces impacting the
trapezoidal sheet.
[0058] The rail supports can be mounted so that a compressive load
and a tensile load are exerted on the trapezoidal sheet in an
alternating manner. Thus the rail supports have to be supported
contacting an upper or lower delimitation of the receiving cavity
during assembly in case their respective T-shaped component has a
clearance in the respective receiving cavity before the T-shaped
component is attached at the respective flank through an attachment
device. In case the trapezoidal sheet has a height difference, a
respective rail support can be still attached at each flank.
[0059] It is not required as a matter of principle that rail
supports are attached at each flank. Rail supports can for example
be attached at every second, third, fourth, etc. flank. By the same
token, rail supports can be alternatively arranged on the
respective sides of the profile rail.
[0060] In addition to the rail supports, upper trapeze supports can
be mounted at the raised beads, wherein the upper trapeze supports
additionally hold the profile rail. The upper trapeze supports can
be advantageously used for example under high suction load or with
insufficient raised bead height of the trapezoidal sheets. Upper
trapeze supports of this type include for example a contact plate
with a clearance hole through which they can be attached at a
raised bead. Furthermore, the upper trapeze supports for example
include a C-shaped support element which engages the receiving
cavity of the profile rail. Thus an additional support of the
profile rail can be facilitated.
[0061] A fourth aspect of the invention relates to a method for
mounting an attachment system according to the second aspect on a
trapezoidal sheet which includes raised beads and associated
flanks, the method including the following steps:
[0062] a) placing the profile rail with its bottom side on raised
beads of the trapezoidal sheet;
[0063] b) inserting the T-shaped element of one of the rail
supports into one of the receiving cavities of the profile
rail;
[0064] c) attaching the rail support at one of the flanks with an
attachment device which extends through a clearance hole of the
rail support;
[0065] d) repeating of steps b) and c) at least once with
respectively one further rail support.
[0066] The method according to the fourth aspect of the invention
facilitates a simple assembly of a profile rail from the attachment
system according to the second aspect with the associated rail
supports. The rail supports can thus be mounted on one side or
preferably on both sides of the profile rail.
[0067] The method according to the fourth aspect of the invention
facilitates transferring the attachment system according to the
second aspect and a trapezoidal sheet into the arrangement
according to the third aspect of the invention. The already recited
variants and advantages also apply analogously for the method
according to the fourth aspect of the invention.
[0068] Since the profile rail is loosely applied to the flat roof
at the beginning of the method and not till then respective rail
supports are attached at suitable flanks, the method according to
the fourth aspect of the invention has a maximum amount of
flexibility. Exactly the required amount of rail supports can be
mounted for a particular profile rail and their positions are
largely selectable at will. Through the lateral assembly of the
supports, the locations where method steps have to be performed are
easily accessible.
[0069] In order to secure a position, this means preventing the
supports from sliding out, a screw with a nut fitting into the
receiving cavity can be attached at rail ends directly adjacent to
the last supports. Thus the rail can move freely during temperature
expansions, but cannot slide out.
[0070] Through the profile rail according to the invention, the
attachment system, the arrangement and the method, solar modules
can be attached at continuous rails at certain points and also in
rows.
[0071] Additional features and advantages of the invention can be
derived from the subsequent descriptions of embodiments with
reference to following figures, wherein:
[0072] FIG. 1 illustrates a first embodiment of a profile rail
according to the first aspect of the invention;
[0073] FIG. 2 illustrates a second embodiment of a profile rail
according to the first aspect of the invention;
[0074] FIG. 3 illustrates the profile rail of FIG. 2 with a
connecting block inserted;
[0075] FIG. 4 illustrates a rail support for an attachment system
according to the second aspect of the invention;
[0076] FIG. 5 illustrates a profile rail and a rail support;
[0077] FIG. 6 illustrates an attachment system according to the
second aspect of the invention;
[0078] FIG. 7 illustrates an arrangement according to the third
aspect of the invention;
[0079] FIG. 8 illustrates a flow diagram of a method according to
the fourth aspect of the invention.
[0080] FIG. 1 illustrates a cross-sectional view of a first
embodiment of a profile rail 1000 according to the first aspect of
the invention. The profile rail includes a base plate 1100 whose
bottom side forms a bottom side 1110 of the profile rail. The
bottom side 1110 includes a notch 1120 so that the bottom side 1110
is only planar in sections. The bottom side 1110 as long as it is
flat forms a contact surface of the profile rail on which the
profile rail rests in assembled condition.
[0081] Above the base plate 1100, the profile rail includes a first
receiving cavity 1200 for rail supports which is partially closed
towards the left side in FIG. 1. For this purpose, lateral bars
1220, 1230 are being used between which a lateral opening 1210 is
formed. Besides the opening 2010 and the two lateral bars 1220,
1230, the first receiving cavity 1200 is defined C-shaped. This is
achieved by two horizontal arms 1240, 1260 and a vertical arm 1250,
wherein the two horizontal arms 1240, 1260 correspond to the
horizontal C-bars, wherein the vertical arm 1250 corresponds to a
vertical C-bar.
[0082] A second receiving cavity 1300 for rail supports is arranged
mirror-inverted to the first receiving cavity 1200 for rail
supports, wherein the second receiving cavity is partially closed
towards a right side of FIG. 1 through two lateral bars 1320, 1330.
Like for the first receiving cavity 1200, a lateral opening 1310 is
formed between the lateral bars 1320, 1330 of the second receiving
cavity 1300. Also the second receiving cavity 1300 is defined
C-shaped through two horizontal arms 1340, 1360 and a vertical arm
1350.
[0083] Additionally, the profile rail 1000 includes a third
receiving cavity 1400 which is also arranged above the base plate
1100 and also above the first and the second receiving cavity 1200,
1300. The third receiving cavity 1400 includes an inner profile
1500 which is formed from two horizontal bars 1510, 1520. Between
the two horizontal bars 1510, 1520 which have identical distances
from the base plate 1100, an opening 1410 is configured that is
oriented away from the bottom side 1110 of the profile rail. As
apparent in FIG. 1, the opening 1410 is oriented in upward
direction when the profile rail rests with its bottom side
1110.
[0084] The first and the second receiving cavity 1200, 1300 for
rail supports are used for receiving suitable connection devices of
rail supports in order to mount the profile rail 1000 on a
trapezoidal sheet, wherein in particular T-shaped and U-shaped
connection devices are suitable. Thus a form-locking connection
between the profile rail 1000 and the respective rail support can
be established. When the rail support is subsequently connected
with the trapezoidal sheet, a form-locking connection is also
created between the profile rail 1000 and the trapezoidal sheet,
with which the profile rail 1000 on the trapezoidal sheet.
[0085] In the third receiving cavity 1400, suitable connection
devices of module attachment elements or also complete module
attachment elements can be received. The delimitation recited supra
of the third receiving cavity 1400 through the horizontal bars
1510, 1520 facilitates a form-locking connection between the module
attachment element and the profile rail 1000 when the connection
devices are configured in a suitable manner. In turn a solar
module, for example a photovoltaic module or a solar collector
module can be attached at the module attachment element, wherein
the solar module is mounted on the trapezoidal sheet in this
manner.
[0086] FIG. 2 illustrates a second embodiment of a profile rail
2000 according to the first aspect of the invention. The profile
rail 2000 includes a base plate 2100 which forms a completely flat
bottom side 2110 of the profile rail. Laterally with respect to the
profile rail, similar to the profile rail 1000 illustrated in FIG.
1, a first and a second receiving cavity 2200, 2300 for rail
supports are configured. They are respectively defined in outward
direction through lateral bars 2220, 2230 and 2320, 2330 between
which respective lateral openings 2210, 2310 are configured. Also
the first and the second receiving cavity 2200, 2300 for rail
supports are respectively delimited C-shaped besides the lateral
bars 2220, 2230, 2320, 2330 and the openings 2200, 2300.
[0087] The profile rail 2000 furthermore includes a third receiving
cavity 2400 which forms an opening 2410 that is oriented away from
a bottom side 2110 of the profile rail. The third receiving cavity
2400 is laterally defined through a first inner wall 2420 and a
second inner wall 2430 and defined in downward direction by the
base plate 2100.
[0088] An inner profile 2500 is configured in the third receiving
cavity 2400, wherein the inner profile includes a first crank 2510,
a first contact surface 2530 and a bar 2550 with a second crank
2520 and a second contact surface 2540. The first crank 2510 and
the first contact surface 2530 both protrude from the first inner
wall 2420. The first crank 2510 is thus further remote from the
base plate 2100 than the first contact surface 2530. Furthermore,
the first contact surface 2530 protrudes further into the third
receiving cavity 2400 than the first crank 2510. At an end of the
bar 2550 that is remote from the base plate 2100, the crank 2520
and the second contact surface 2540 are arranged. The second crank
2520 is oriented away from the first inner wall 2420 like the first
crank 2510. The second contact surface 2540 has the same distance
from the base plate 2100 as the first contact surface 2530. The bar
2550 extends perpendicular to the base plate 2100.
[0089] The functions of the bottom side 2110 and of the first and
second receiving cavities 2200, 2300 for rail supports are
identical to those of the bottom side 1110 and the first and second
receiving cavity 1200, 1300 for rail supports of the profile rail
1000 which is illustrated in FIG. 1. Therefore, a repeated
description is omitted.
[0090] The inner profile 2500 facilitates forming a form locking
connection with suitable connecting blocks. Details are
subsequently described with reference to FIG. 3.
[0091] FIG. 3 illustrates the profile rail 2000 of FIG. 2 with an
inserted connecting block 3000. The connecting block 3000 includes
a contact surface 3100 and is configured U-shaped on one side. Thus
the connecting block includes a first engagement surface 3300 at
its top side and a second engagement surface 3400 at a top side of
a lower arm of the U. A borehole 3200 extends through the
connecting block 3000 which facilitates connecting the connecting
block through a threaded bolt with an element above the profile
rail. An element of this type can be for example another profile
rail, a solar module like a photovoltaic module or a solar
collector module or also a spacer.
[0092] In order to mount the connecting block 3000, it is initially
placed with its contact surface 3100 onto the first contact surface
2530 and the second contact surface 2540 of the profile rail 2000.
This facilitates inserting plural connecting blocks after the
profile rail is mounted on a trapezoidal sheet, wherein wedging,
pivoting or falling out of the connecting blocks can be excluded.
When an upward directed force is exerted upon the connecting block
3000 through a bolt inserted into the borehole 3200, the connecting
block is pulled upward and away from the base plate 2100. Thus the
first engagement surface 3300 comes into engagement with the first
crank 2510; furthermore the second engagement surface 3400 also
comes into engagement with the second crank 2520. Thus the
connecting block 3000 seizes with the profile rail 2000 so that an
attachment of the element that is arranged above the profile rail
2000 is facilitated through the form locking connection. Overall,
the combination of the connecting block 3000 with the profile rail
2000 facilitates a particularly simple assembly of the elements
arranged above the profile rail 2000.
[0093] FIG. 4 illustrates a rail support 4000 for an attachment
system according to the second aspect of the invention. The rail
support 4000 includes a main element 4100 which has an elongated
shape. Proximal to one end, there is a T-shaped component which
includes a bar 4220 and an extension 4210. The bar 4220 is thus
configured parallel to the main element 4100 and connected with the
main element through the extension 4210. The main element 4100
furthermore includes a protrusion 4300 in which two clearance holes
4310, 4320 are configured. In a direction perpendicular to the
plane illustrated in FIG. 4, the rail support 4000 has a constant
thickness.
[0094] The T-shaped component 4200 when mounting a profile rail
1000, 2000 according to the first aspect of the invention is used
for forming a form-locking connection with one of the receiving
cavities 1200, 1300, 2200, 2300 of the respective profile rail. For
this purpose, the bar 4220 of the T-shaped component 4200 has to be
placed initially substantially parallel to the longitudinal
extension of the respective opening 1210, 1310, 2210, 2310.
Subsequently, the bar is inserted through the opening into the
respective receiving cavity. After insertion, the support 4000 is
rotated about the extension 4210. This establishes a form-locking
connection between the support 4100 and the profile rail 1000, 2000
so that the support 4000 cannot be removed anymore without turning
the profile rail back. In order to mount the respective profile
rail on a trapezoidal sheet, the rotation is performed so that the
main element 4100 essentially contacts a flank of a vertical
support fin flatly. Subsequently, suitable attachment devices, for
example bolts or rivets, are inserted through one or both clearance
holes 4310, 4320 and driven into the material of the trapezoidal
sheet. When this is performed so that a tight non-moving connection
between the support 4000 and the trapezoidal sheet is formed, also
the profile rail is supported on the trapezoidal sheet through the
support 4000.
[0095] FIG. 5 illustrates a profile rail 1000 according to the
first embodiment as illustrated in FIG. 1 with an inserted and
rotated rail support 4000. It is evident that the bar 4220 of the
T-shaped component 4200 of the rail support 4000 which is inserted
in the second receiving cavity 1300 of the profile rail 1000 forms
a form locking connection with the vertical arm 1350 and the side
arms 1320, 1330. It is furthermore apparent that the bar 4220 has
clearance in upward direction in the second receiving cavity 1300.
This facilitates a compensation of unevenness and tolerance
relative to temperature induced length changes of the components
used. It is apparent from the described form locking connection
that eventually also the profile rail 1000 is attached through
attaching the rail support 4000 at a flank of the trapezoidal
sheet.
[0096] FIG. 6 illustrates an embodiment of an attachment system
according to the third embodiment of the invention. The attachment
system includes two profile rails 2000 according to the second
embodiment and twelve rail supports 4000. With respect to the
configuration of the profile rails 2000, reference is made to FIG.
2. With respect to the configuration of the rail supports 4000,
reference is made to FIG. 4.
[0097] The attachment system of FIG. 6 facilitates parallel
mounting of two profile rails on a trapezoidal sheet. Each of the
two profile rails 2000 can thus be attached at the trapezoidal
sheet with six rail supports 4000. A parallel assembly of two
profile rails is typically used to mount a series of solar modules.
Each module contacts each of the two profile rails. The solar
modules are attached at the profile rails with suitable module
attachment elements which come into engagement with the inner
profiles 1500, 2500 of the profile rails.
[0098] However, it is appreciated that attachment systems according
to the invention are not limited to a number of two profile rails
and twelve rail supports. Rather, any other useful combination of
profile rails and supports can be used and can be considered for
example as a kit for mounting solar modules.
[0099] FIG. 7 illustrates an arrangement 7000 for attaching solar
modules with an attachment system according to the second aspect of
the invention and with a trapezoidal sheet 7500.
[0100] The trapezoidal sheet 7500 includes beads 7510 and raised
beads 7540 arranged there between. Two flanks 7520, 7530 are
associated with each raised bead, wherein the flanks connect
respectively adjacent beads 7510 and raised beads 7540. The beads
7510, flanks 7520, 7530 and the raised beads 7540 are bent from a
single continuous metal plate.
[0101] The profile rail 2000 contacts the raised beads 7540 of the
trapezoidal sheet 2500 with its bottom side 2110. On both sides of
the profile rail respective supports 4000 are applied thus so that
their respective T-shaped components form a form-locking connection
with the delimitations of the first and second receiving cavities
2200, 2300. Furthermore, the supports 4000 are attached with screws
7100 at respective flanks 7520, 7530. Through forming a connection
of the attachment on the profile rail already described with
reference to FIG. 5, also the profile rail 2000 is supported on the
trapezoidal sheet 7500. Mounting the rail supports 4000 on both
sides facilitates additional stabilization of the profile rail on
the raised beads.
[0102] FIG. 8 illustrates a method for mounting an attachment
system according to the second aspect of the invention on a
trapezoidal sheet. As illustrated in FIG. 7 the trapezoidal sheet
includes raised beads and associated flanks.
[0103] Initially a first profile rail from the attachment system is
placed in a step S81 with its bottom side on raised beads of the
trapezoidal sheet. Subsequently the T-shaped portion of one of the
rail supports out of the attachment system is inserted in a step
S82 into one of the receiving cavities of the profile rail. The
rail support is subsequently turned in step S83 so that its main
element contacts one of the flanks and the rail support is attached
at the flank through a screw. Steps S82 of inserting and S83 of
attaching the rail supports are repeated several times in step S84
until a sufficient number of rail supports is mounted in order to
fixate the profile rail on the raised beads.
[0104] Subsequently, a second profile rail from the attachment
system is applied parallel to the first profile rail in step S85.
The second profile rail has to be offset from the first profile
rail so that applying and attaching modules is feasible.
[0105] The steps S82 through S84 are subsequently also repeated for
the second profile rail until the second profile rail is mounted on
the trapezoidal sheet with sufficient strength.
[0106] Thus it is not necessary that the second profile rail is
attached at the same flanks as the first profile rail. Rather, both
profile rails can be attached independently from one another as
required by boundary conditions like for example compensating
unevenness, providing expansion tolerance or presence of obstacles
on the trapezoidal sheet.
* * * * *