Tightening arrangement and mounting arrangement for a solar cell module

Abstract

A clamping system for a solar module comprises an assembly with at least one substantially C-shaped longitudinal guide rail (110) and first and second supports. These supports (120, 130) are substantially L-shaped, forming an angle with two legs. A first leg comprises a first extended straight section (121, 131); the second angled leg or second section (122, 132) has a gripping section (123, 133) at its end. This gripping section serves to firmly clamp the frame of a solar module. [0002] The supports (120, 130) are inserted into the longitudinal ends of the guide rail (110). For this purpose, the interior of the guide rail (110) has a guide dimensioned such that the first section (121, 131) or leg of the supports (120, 130) slides therein.[0003] An eyelet (128) in the support (120) and in the guide rail (118) can be connected by means of a spring (250) so that the support (120) is inserted into the guide of the guide rail (110) and exerts a tensile force on the gripping section (123, 133). [0004] A mounting system for solar cell modules for facades comprises the aforementioned clamping system, a support rail, and a solar cell module.

Description

[0001] The present invention relates to a clamping arrangement for a solar module. A clamping arrangement is defined as an assembly designed and suitable for securely clamping a solar module or another plate-shaped component of comparable dimensions. A mounting arrangement further comprises a support rail for attachment to a substructure and the clamping mechanism for the solar module, which are together inserted into the support rail. BACKGROUND

[0002] In the following, solar panel, solar module, or solar cell module refers to a flat arrangement of numerous interconnected solar cells. Such solar modules are typically encapsulated to protect them from unwanted environmental influences, equipped with electrical connectors, and sold ready for installation.

[0003] Solar cell modules typically have a translucent front element (preferably glass) and a protective component against the elements on their back. This component can be, for example, an adhesive film, a back glass panel, or a plastic sheet. The edges are sealed to prevent the ingress of atmospheric oxygen and liquids. Within this protective sandwich structure, in addition to the actual solar cells, are the current-carrying conductors and other electronic components, depending on the size, type, and power output of the solar cell module. A solar module is generally enclosed at the edges by a metal frame, which also serves as the mechanical attachment point to a support structure.

[0004] This metal frame must be stable enough to withstand wind forces and snow loads acting on the solar module, in addition to the weight of the solar module itself, and regardless of the installation position (vertical, inclined, horizontal).

[0005] To date, most solar modules have been mounted on the roofs of residential or industrial buildings, both pitched and flat. Often, the solar modules are oriented towards the south and tilted to optimize the average annual energy yield. However, the installation of solar modules on building facades is becoming increasingly important.

[0006] Due to their installation on roof surfaces, solar modules experience a reduction in performance when they become dirty or are (partially) covered by leaves and snow. Mounting them on a building facade, on the other hand, offers advantages: less dirt accumulates, and snow is not a problem. Furthermore, if a solar module is integrated into a ventilated, rainscreen facade, a purely passive building envelope becomes a partially active, energy-generating surface.

[0007] To reap these benefits without excessive effort, several prerequisites must be met: A solar cell module must be securely mounted to meet the aforementioned stability requirements. Fastening via screws, rivets, or other fasteners must only occur at specific points on the metal frame to prevent damage to the sandwich structure described above. Damage to the cells could allow moisture and oxygen to penetrate, causing oxidation or short circuits. Therefore, such mounting points are often specified or pre-installed by the manufacturer. Thirdly, the mounting should be easily removable should one of the modules become defective or damaged in a facade. STATE OF THE ART

[0008] Several solutions to this problem exist in the current state of the art, such as mounting openings (holes, slots) provided by the manufacturer around the solar cell module, tabs, or similar anchor points. However, these solutions require that the actual facade substructure takes the location of the prescribed mounting points into account. Therefore, the facade design must be adapted to the intended type, size, and mounting method of the solar cell modules.

[0009] The invention described below is based on the fundamental principle of a holding structure consisting of two identically shaped, inverted, and interlocking profiles. This was demonstrated, for example, in its basic features in German patent application DE 93 08 171.5. A profile, preferably extruded as a strand, is horizontally attached to a substructure to act as a receptacle. A section of the same profile, rotated 180°, can be positively engaged in the receptacle.

[0010] Document DE 10 2011 084213 A1 describes a clamping arrangement according to the preamble of claim 1.

[0011] The object of the invention is to propose a mounting that does not require attachment points provided on the frame of the solar cell module, is easy to attach and detach, and is flexible in its handling with respect to the supporting substructure. DESCRIPTION OF THE INVENTION

[0012] This problem is solved by a clamping arrangement according to the features of independent claim 1. Furthermore, a mounting arrangement on a facade is described. The dependent claims each describe variants and embodiments.

[0013] An inventive clamping arrangement for a solar module comprises an assembly with at least one substantially C-shaped, longitudinally extended guide rail of length s and a first and a second bracket that allow for clamping. To allow for high flexibility when using the proposed clamping arrangement with solar modules of varying sizes and, at the same time, to minimize the visibility of the mounting on the facade, the length s of the guide rail is chosen to be smaller than the dimensions of the solar module at the point where it is to be clamped. The brackets are arranged at the longitudinal ends of the guide rail and attached within the interior of the guide rail. The interior refers to the cavity or recess defined by the C-shape.

[0014] The C-shape can be realized, as in the aforementioned prior art, as a hollow box-like profile open on one side in cross-section. The edge regions of this opening will also be referred to as end sections in the following.

[0015] The two brackets are essentially L-shaped, forming an angle. The first leg of the angle has a first, extended, straight section of length l, width b, and thickness t. The second leg has a second section angled relative to the first leg, which also features a gripping section at its open end. This gripping section is dimensioned to securely grip the frame of a solar module. This design ensures that the gripping section can securely grip and hold the frame, both in terms of dimensions and force.

[0016] These two brackets and the guide rail have openings for fasteners such as screws or rivets, which allow the brackets to be fixed to the guide rail in a secure position.

[0017] According to the invention, a guide is provided inside the guide rail, which can accommodate the first section (leg) of the brackets. In the technically accepted understanding, a guide is a device in which a component is movable in at least one spatial direction, but is limited in other spatial directions.

[0018] For this purpose, the clamping arrangement, specifically the guide, is designed to essentially have two U-shaped grooves spaced apart from each other, with their openings facing each other. As is typical, the U-shape consists of two essentially straight, bounding side walls and a connecting elbow between them, which forms the groove base.

[0019] To accommodate and guide the first sections of the guide rail in a (longitudinally) slidable manner, the dimensions of the guide are chosen such that each groove has a width w and the grooves are spaced a certain distance d apart, measured from groove bottom to groove bottom. The width w of the grooves must therefore be slightly larger than the thickness t of the first sections to allow for some play. The same applies to the distance d; it is chosen to be slightly larger than the width b of the first section (leg) of the first or second support.

[0020] According to the invention, a first side wall for each of the two U-shaped grooves is formed jointly by an outer wall of the guide rail.

[0021] The second side wall is formed as a separate, rib-shaped projection of height h, arranged at a parallel distance w from the first side wall. Preferably, the outer wall of the guide rail that forms approximately the center of the C-shape is selected as the first side wall.

[0022] The dimensions of the guide, and specifically of the second side walls, can be described as follows: w < h < 5w. In other words, the height of the second side wall is dimensioned snugly, at least as high as the groove is wide, and preferably no more than five times the width w. This is sufficient for the guide's function. Since the guide consists of two opposing grooves, and there is no compelling need to guide the first section of the first or second support in a completely enclosing slot, a further preferred condition can be specified: twice the height of the second side wall should be (significantly) smaller than the distance d between the grooves, i.e., 2h < d. As mentioned above, the distance d, the opening of the guide, is chosen to be slightly larger than the width b of the first section (leg) of the first or second support, mathematically d ≈ b.

[0023] The position of the brackets, when arranged in the guide as intended, can be secured relative to the guide rail using fasteners. These fasteners can be inserted through or positioned in overlapping openings in both the guide rail and the brackets. It is advantageous if the first bracket has an elongated hole, as this allows for relative adjustability between the guide rail and the first bracket.

[0024] According to the invention, the guide rail has a first eyelet that extends perpendicularly from the first side wall into the interior of the guide rail. This eyelet is positioned at a distance from the end of the guide rail that is greater than the length l of the first section of the bracket. This ensures that the first eyelet does not act as a stop for the bracket inserted into the guide. Such an eyelet can be implemented, for example, as a surface-mounted component or as a partially punched-out and bent portion of the guide rail's side wall.

[0025] As a counterpart to the first eyelet, a second eyelet is implemented on the first bracket, which is positioned on the narrow side of the first section opposite the gripping section.

[0026] When the bracket is inserted into the guide, it is inserted with the second eyelet facing forward. The second eyelet extends perpendicularly from the plane of the first section and points inwards, provided the first bracket is correctly positioned in the guide rail. In this case, the line of sight through the first and second eyelets will also run parallel to the plane of the first side wall of the guide rail.

[0027] The purpose of the eyelets is that the first and second eyelets can serve as attachment points for a spring which, when the first bracket is correctly installed in the guide, exerts a tensile force between the guide rail and the first bracket. This pulls the bracket into the guide, thereby applying a tensile force to the gripping section. A person skilled in the art can implement the spring described here as a coil spring with end hooks for the eyelets or by using equivalent elastic clamping elements.

[0028] The provision of the eyelets and the attachment of the spring were described for the first bracket because one clamping device per clamping assembly is usually sufficient. The second bracket can be pre-adjusted, but rigidly connected to the guide rail, for example, via a selection of pre-drilled holes. In the described case, the clamping force would be provided solely by the clamping device between the first bracket and the guide rail. An additional securing option can be provided by incorporating a slot in the first section of the first bracket in conjunction with a single through-hole in the guide rail. During pre-assembly, a loose screw / nut connection would be used. After a solar cell module has been inserted into such a prepared clamping arrangement, the clamping arrangement can be fixed in its final position by tightening the loose screw / nut connection.

[0029] The guide rail described here can be manufactured as an extruded aluminum profile with a substantially uniform cross-section, as can the support rail described below. Eyelets and through-holes can be added in further processing steps.

[0030] The brackets can also be made of aluminum as stamped and bent parts, or alternatively from thin sheet steel by stamping and bending.

[0031] The following describes a mounting system consisting of a clamping assembly, solar module, and mounting rail. This system is primarily intended for use on facades, but is not limited to this application. It can also be used for arrangements deviating from the vertical.

[0032] A mounting system with a solar module comprises the clamping assembly described above and a mounting rail. The mounting rail is designed to be attached horizontally to a load-bearing substructure. The term "substructure" typically refers to supporting structures that are attached to or at a certain distance from a load-bearing (exterior) building wall and serve as a receptacle for suspended facade elements. These elements then form the visible facade. The combination of substructure and facade cladding is then referred to as the building envelope.

[0033] For assembly, the clamping arrangement is dimensioned (l, b, t, h, s...), particularly in the gripping area, so that it can securely grip the edge or frame of a solar module. It is advantageous for assembly if both the guide rail and the mounting rail have a substantially C-shaped cross-section. The open end sections of the C-profile are advantageously shaped so that they interlock when the guide rail is hooked into the mounting rail, with the openings of the C aligned with each other.

[0034] It is particularly advantageous if the first and second end sections of the guide rail and the first and second end sections of the support rail are designed differently, but the first end section of the support rail is modeled after the first support section of the guide rail, and the second end section of the support rail after the second support section of the guide rail. As in the prior art, these end sections can be identical in pairs or compatible to such an extent that the described interlocking and locking can be achieved. Locking here is not meant as an irreversible process, but rather as a connection that is permanently secured, for example, by its own weight, yet can be released.

[0035] A mounting arrangement of the type described can, of course, for particularly large or heavy solar panels, provide two (or more) parallel, offset guide rails to secure the solar panel. These are hooked into a corresponding number of support rails.

[0036] Depending on the task or regulations, a specialist will supplement the previously described clamping arrangement or mounting procedure with securing devices. For example, the position of the gripping section on the frame of a solar cell module can be secured with a locking screw or rivet. Similarly, the connection between the guide rail and the mounting rail can be secured with a locking screw. Such a requirement may arise when high wind loads are expected on a building facade. DESCRIPTION OF THE FIGURES

[0037] The invention will now be explained by way of example with reference to the accompanying drawings and preferred embodiments. Figure 1 shows a comparison of a 200 mm support rail and a 110 mm guide rail. Figure 2 shows a support rail 200 and a guide rail 110 in the suspended, locked state. Figure 3 This is a 3D view of a guide rail 110 with inserted brackets 120 and 130 from the panel side. Figure 4 shows a guide rail 110 without brackets. Figure 5 A first bracket is shown at 120. Figure 6 A second bracket is shown at 130. Figure 7 shows a top view of an end piece of a guide rail 110. Figure 8 shows an assembly of guide rail 110 and first bracket 120, connected via spring 250.

[0038] Figure 1The figure shows a mounting rail 200 (left) and a guide rail 110 (right). The illustration depicts the state before the two profiles are attached and locked. A solar module or substructure is omitted from this illustration. The first end section (top) 281 of the mounting rail 200 is angled, while the other end section 282 (bottom) is hook-shaped. The C-shape of the mounting rail 200 opens to the right in the drawing, and that of the guide rail 110 opens to the left. The opening between the end sections 181 and 182 and the essentially box-shaped profile of the guide rail 110 form an interior space 140. Part of this interior space 140 is occupied by the guide 150, which is marked here as a vertical element. In the assembled state, this space would be occupied by the first section 121 or 131 of a bracket 120 or 130, respectively (not explicitly shown).In this embodiment, the guide is formed by two opposing U-shaped grooves 151 and 152, spaced a distance d apart so that their openings are aligned. The lower groove 152 in the image consists of a left (second) side wall 157 and the outer wall of the guide rail 110, which forms the right (first) side wall 155. The distance between the side walls is marked w. The second (upper) groove 151 uses the same outer wall as its side wall 155 but has its own second side wall 156. The height h of both side walls is the same. This is advantageous for manufacturing, but not essential. The height h is usually chosen to ensure the proper functioning of the guide 150. An excessively high design (large h) is not necessarily conducive to the stability of the second side walls 156 and 157 and increases the risk of jamming of an inserted first support section.

[0039] The distance d, measured from groove bottom to groove bottom, corresponds within the limits mentioned above to the width b of a support section.

[0040] Furthermore, it is advantageous to coordinate the profiles of the support rail and guide rail on the one hand, as well as the guide rail and the width of the first section 121, 131 of the bracket 120, 130, in such a way that the design of the guide 150 does not become too complex. The size and weight of the solar cell module to be held also play an important role in this.

[0041] Figure 2The diagram shows a support rail 200 and a guide rail 110 installed in a cross-section. A bracket is not shown. The position of a solar module 130 is indicated, as is the position of a substructure 300, to which the support rail 200 is attached using a screw 230. The substructure can be made of, for example, wood, aluminum, or steel profiles. The type and dimensions of this support structure are determined by building regulations and safety requirements and are implemented accordingly. Figure 2 shows in particular how the (not marked again here) end sections 181, 182, 282, 281 interlock.

[0042] Figure 3The figure shows a front view of a guide rail 110 with inserted brackets 120 and 130 in an oblique 3D plan view. The opposing gripping sections 123 and 133, which together form a clamp, create the receiving space for a solar panel or, if required, a similarly sized facade cladding element. A three-sided cutout is marked 119. The resulting tongue is provided with an opening as an eyelet during the manufacturing process and bent at a right angle (towards the rear in the drawing). The length s of the guide rail 110 is extended on both sides by the brackets 120 and 130, thus the guide rail 110 remains invisible from the (intended) panel side.

[0043] Figure 4Figure 1 shows a guide rail 110 without mounted brackets. Reference is made to the position of the open longitudinal ends 125 and 135. The openings 161 and 162 are shown as square cutouts; this allows the use of anti-rotation carriage bolts to secure the brackets to the guide rail.

[0044] Figure 5Figure 1 shows the first L-shaped bracket 120. It consists of the first leg 121 (first section) and the second section 122, which is arranged at right angles to it and transitions into the gripping section 123. The gripping width d corresponds to the frame depth of a solar panel to be held. The first leg has the dimensions l x b and a thickness t. The thickness t and width b are necessarily the same for both brackets because both use the same guide 150 in the guide rail 120. The first section 121 is equipped with an elongated hole 160. Furthermore, the second tab 128 is attached to the open end of the first section 121. It is also shown as a punched and bent element.

[0045] Figure 6Figure 1 shows the second bracket 130, which is simpler in design than the first bracket 120. Instead of an elongated hole, the first section 131 in the illustrated embodiment has two normal bores 163 and 164. An eyelet is not provided. The gripping section 133 is identical in design to that of the first bracket 120 ( Figure 5 ).

[0046] In Figure 7 A top view of a cross-section or longitudinal end 125 of a guide rail 110 is shown. The position of a first eyelet 118 in the depth or course of the profile is marked. The position of the grooves 151 and 152 is also highlighted.

[0047] Figure 8Figure 1 shows a perspective view of the assembly of guide rail 110 and bracket 120. A bracket 120 is inserted into the guide 150 (not marked) with its first section 121. The second section 122, with its gripping section 123, extends beyond the longitudinal end 125 of the guide rail 110. The two eyelets 118 and 128 are connected by a suspended spring 250, which exerts a tensile force from the guide rail 110 onto the bracket 120. The elongated hole 160 allows a view of a square opening 161 (not marked) in the guide rail.

[0048] Finally, a typical assembly process will be briefly described: A guide rail 110, dimensioned according to the specifications for a solar cell panel, and two brackets 120 and 130 are prepared. The second bracket is installed as shown in... Figure 3The guide rail 110 is inserted as shown on the right and screwed to opening 163 or 164 via opening 162. A first bracket 120 is then inserted into the guide 150 at the other end of the guide rail 110. A loose screw-nut connection is prepared through the elongated hole 160 and the opening 161 (not mandatory depending on the load case). A spring 250 can then be inserted as shown in... Figure 8 The modules are shown and can be hung as shown. If the dimensions of the solar cell module to be mounted are known, this pre-assembly can be carried out by the manufacturer or installer.

[0049] The solar cell module can then be inserted into the clamping assembly. For this, the end of the clamping assembly with the second, fixed bracket is preferably hooked onto the frame of the solar cell module. The first bracket is pulled out of its guide against the tension of the spring until the gripping section can be guided over the other frame part. The spring is then released until the gripping section fits snugly against the frame. The clamping assembly is now in contact with the solar module. Depending on the requirements, the gripping section can also be fitted with damping strips, compensating elements, or adhesives on its inner surface where it contacts the frame.

[0050] Depending on the requirements, a second clamping arrangement can be attached to the solar cell module in the same way. Both clamping arrangements can be fine-tuned in position, for example by using a positioning gauge on the frame.

[0051] Higher fastening quality can be achieved if the aforementioned screw connection is tightened through slot 160 and opening 161. The clamping force and position, predetermined by the choice of spring, are thus fixed. Depending on the requirements, additional mechanical securing measures can be taken between the gripping section and the solar panel frame, e.g., by gluing or screwing.

[0052] A particular advantage of the inventive clamping arrangement is that, due to its

[0053] The construction method allows a single installer to assemble the panels in the manner described. Due to pre-assembly, on-site installation of the panels – provided the substructure is already in place – is achieved simply by hooking the guide rail into the support rail.

Claims

1. Clamping arrangement (100) for a solar module comprises an assembly having at least one longitudinally extended guide rail (110) with a substantially C-shaped cross-section and a length s, and a first and a second holder (120, 130) - arranged at the longitudinal ends (125, 135) of the guide rail (110) and - are fastened in an interior space (140) of the guide rail (110); wherein each of the holders (120, 130) is substantially L-shaped; - having a first, extended, straight section (121, 131) of length l and width b and - a second section (122, 132) angled thereto, which has a gripping section (123, 133) designed to form-fit around the frame of a solar module; wherein both holders (120, 130) and the guide rail (110) have openings (160-164) for fastening elements that allow the holders to be fixed to the guide rail in a secure position, and the interior space (140) of the guide rail (110) has a guide (150) for accommodating and movably guiding the first sections (121, 131) of the holders (120, 130) in the guide (150); wherein the guide (150) substantially comprises two U-shaped grooves (151, 152) which - are arranged spaced apart from each other and - each have a width w and a distance d from groove bottom to groove bottom, characterized in that - the openings of the U-shaped grooves (151, 152) face each other and - a first side wall (155) of the two U-shaped grooves (151, 152) is formed jointly by an outer wall of the guide rail (110) and - the second side wall (156, 157) is formed in each case as a separate, rib-shaped projection of height h, which is arranged at a parallel distance w from the first side wall (155); and the guide rail (110) - has a first eyelet (118) extending at right angles from the first side wall (155) into the interior space (140) of the guide rail (110), and the first holder (120) - has a second eyelet (128) arranged on the narrow side of the first section (121) opposite the gripping section (123); and extends at right angles away from the plane of the first section (121) and points into the interior space (140) when the first holder (120) is correctly arranged in the guide (150) of the guide rail (110); wherein - the first eyelet (118) and second eyelet (128) are attachment points for a spring (250) which, when the first holder (120) is correctly installed in the guide (150), exerts a tensile force between the guide rail (110) and the first holder (120); whereby a tensile force acts on the gripping section (123).

2. Clamping arrangement (100) according to claim 1, characterized in that w < h < 5 w and 2 h << d and d <≈ b applies to the second side walls (156, 157).

3. Clamping arrangement (100) according to claim 1 and 2, characterized in that the position of the holders (120, 130), when correctly arranged in the guide (150), can be secured relative to the guide rail (110) by means of fasteners which are arranged in correspondingly overlapping openings (160-164) in both the guide rail (110) and the holders (120, 130).

4. Clamping arrangement (100) according to claim 1 to 3, characterized in that the first holder (120) has an elongated hole (160).

5. Clamping arrangement (100) according to claim 1 to 4, characterized in that the line of sight through the first (118) and second eyelet (128) runs parallel to the plane of the first side wall (155) of the guide rail (110).

6. Clamping arrangement (100) according to claim 1 to 5, characterized in that the guide rail (110) is manufactured as an extruded aluminum profile with a substantially uniform cross-section.

7. Mounting arrangement for a solar module (310) having a clamping arrangement (100) according to claim 1 to 6, and a support rail (200), wherein the support rail (200) is designed to be attached horizontally to a load-bearing substructure (300); and the clamping arrangement (100) is dimensioned to grip the edge area or frame of a solar module (310) in a securing manner; wherein both the guide rail (110) and the support rail (200) have a substantially C-shaped cross-section; and wherein the open end sections (181, 182, 281, 282) of the C are shaped so that they engage into each other in an interlocking manner when the guide rail (110) is hooked into the support rail (200), wherein the openings of the C are aligned with each other.

8. Mounting arrangement according to claim 7, characterized in that, for securing a solar panel (310), two guide rails (110) arranged in a parallel offset manner are provided, which engage in two corresponding support rails (200).

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