Roof photovoltaic pedestal structure, photovoltaic power generation device and construction method

Abstract

The application discloses a roof photovoltaic pedestal structure, a photovoltaic power generation device and a construction method. The roof photovoltaic pedestal structure comprises at least one prefabricated part, and the prefabricated part comprises a first framework in the shape of a U-shaped character and a thermoplastic resin layer arranged on the inner and outer periphery of the first framework. The roof photovoltaic pedestal structure is suitable for a flexible photovoltaic roof. The prefabricated part is hot melt welded with a waterproof roll of the same material as a roof waterproof roll, so that the waterproof layer is prevented from being damaged by penetration, the lower end surface is in contact, the stability and wind resistance are improved, the roof photovoltaic pedestal structure is not limited by position, is simple to use and has high reliability.

Description

Technical Field

[0001] The present invention belongs to the technical field of flexible single-layer roof photovoltaic technology, and more specifically, relates to a roof photovoltaic base structure, a photovoltaic power generation device and a construction method. Background Art

[0002] Industrial building production workshops, with their large rooftop areas and the absence of surrounding obstructions, are ideal locations for distributed photovoltaic installations. Manufacturing companies are significant energy consumers, and installing photovoltaic panels on their rooftops can transform their energy mix. Increasing the use of clean energy reduces carbon emissions while also offering discounted peak-hour electricity prices, bringing significant economic benefits to businesses.

[0003] At present, a large number of high-end manufacturing industries such as flexible single-layer roof photovoltaic manufacturing, aerospace, data centers and other industrial plants have high requirements for the waterproofing of roof enclosure structures. For industrial buildings with higher importance, flexible single-layer roof is the first choice as the roof waterproofing layer.

[0004] Combining a flexible single-layer roof with distributed rooftop PV typically requires pre-installing PV mounting bases on the main structure during the civil construction phase, followed by waterproofing of the short columns protruding from the roof. However, this approach is limited to newly built industrial plants and cannot be applied to existing industrial buildings with distributed rooftop PV.

[0005] Some base structures can be fixed to a single-layer roof base steel plate, but this requires penetrating the entire waterproof layer, insulation layer, vapor barrier layer, and base steel plate. This complex construction process, and due to differences in structural design and craftsmanship, the penetration site can damage the roof waterproof layer and easily cause leakage.

[0006] In addition, in order to avoid penetrating the existing roof, some construction units directly place the metal bracket on the completed roof, and use homogeneous TPO auxiliary materials to weld and fix them directly to the original roll material by means of a strap. This method has the disadvantages of small welding connection area, direct damage to the existing waterproof roll material when the force is uneven, limited thickness and strength of homogeneous TPO, inability to effectively fix the photovoltaic bracket after irreversible deformation occurs under force, poor wind-resistant ability of the overall structure, and other shortcomings, posing a major safety hazard; the construction is all manual welding operation, and the quality reliability is insufficient.

[0007] Therefore, it is difficult to install rooftop photovoltaics on the existing flexible single-layer roof structure in the later stage. The construction is complicated and there is a risk of damaging the roof, causing water leakage and insufficient wind resistance. Summary of the Invention

[0008] The present application aims at solving the problems of the prior art, and provides a roof photovoltaic pedestal structure.

[0009] To achieve the above object, the present application provides a roof photovoltaic pedestal structure, comprising:

[0010] At least one prefabricated part, the prefabricated part comprising:

[0011] A first framework in the shape of a Chinese character'';

[0012] A thermoplastic resin layer arranged on the inner and outer periphery of the first framework.

[0013] Optionally, the prefabricated parts are arranged at intervals and further comprise:

[0014] At least one first connecting plate, two ends of the first connecting plate being connected with two adjacent prefabricated parts, respectively;

[0015] Two second connecting plates, the two second connecting plates being arranged at the mutually farthest ends of two farthest prefabricated parts and being flush with the first connecting plate;

[0016] The first connecting plate and the second connecting plate are of the same structure, the first connecting plate comprising a second framework flush with the lower end of the first framework, and the thermoplastic resin layer being arranged on the outer periphery of the first framework and the second framework.

[0017] Optionally, further comprising a groove arranged on the lower side of the first connecting plate and the second connecting plate and passing through the directly below of the prefabricated part.

[0018] Optionally, the width of the prefabricated part is consistent with the width of the second connecting plate, and the width of the first connecting plate is twice the width of the second connecting plate.

[0019] Optionally,

[0020] The first framework comprises at least one of a stainless steel wire woven mesh framework, a stainless steel mesh framework, a polyester mesh cloth framework and a nylon mesh cloth framework.

[0021] The thermoplastic resin layer comprises at least one of a thermoplastic polyolefin layer, a polyvinyl chloride layer and a ketone vinyl ester polymer layer.

[0022] Optionally, the thickness of the prefabricated part is 2-10 mm, and the thermoplastic resin layer is formed on the outer periphery of the first framework by layered mold pressing or integral injection molding.

[0023] A roof photovoltaic power generation device, comprising:

[0024] The above-mentioned roof photovoltaic base structure.

[0025] Optionally include:

[0026] two rooftop photovoltaic base structures;

[0027] The roof photovoltaic base structure includes a plurality of prefabricated parts, and the plurality of prefabricated parts are arranged at intervals on the upper side of the flexible single-layer roof;

[0028] Two first-shaped steel pipes, respectively passing through the plurality of prefabricated parts and parallel to each other;

[0029] Photovoltaic panels are arranged on the upper sides of the two first-shaped steel pipes through a connecting structure;

[0030] The connection structure includes two second-shaped steel pipes and multiple positioning pieces. The two second-shaped steel pipes are arranged in parallel at intervals on the upper ends of the two first-shaped steel pipes to form a well-shaped structure. The photovoltaic panels are arranged on the upper sides of the two second-shaped steel pipes.

[0031] A roof photovoltaic base structure construction method, comprising:

[0032] Adjust hot air welding equipment to preset air volume and temperature;

[0033] Heating the lower end surface of the prefabricated component and the exposed surface of the waterproof membrane to a predetermined temperature respectively;

[0034] The heated prefabricated part and the heated exposed surface are bonded together until they are cooled and fixed to form a photovoltaic base structure.

[0035] Optionally, the welding peel strength between the lower end of the prefabricated component and the waterproof membrane layer is greater than 4 N / mm, and the tear strength of the thermoplastic resin layer is less than the tear strength of the waterproof membrane.

[0036] The present invention provides a roof photovoltaic base structure, which has the following beneficial effects:

[0037] 1. The roof photovoltaic base structure is suitable for flexible photovoltaic roofs. By using prefabricated parts made of the same material as the roof waterproof membrane and hot-melt welding with the waterproof membrane, penetration and damage to the waterproof layer can be avoided. The lower end surface contact improves stability and wind resistance while being unrestricted by position. It is simple to use and highly reliable.

[0038] Other features and advantages of the present invention will be described in detail in the following detailed description. BRIEF DESCRIPTION OF THE DRAWINGS

[0039] The above and other objects, features and advantages of the present invention will become more apparent through a more detailed description of exemplary embodiments of the present invention with reference to the accompanying drawings, wherein like reference numerals generally represent like components throughout the exemplary embodiments of the present invention.

[0040] Figure 1 A schematic structural diagram of a rooftop photovoltaic base structure according to an embodiment of the present invention is shown.

[0041] Figure 2 A schematic structural diagram of a first connecting plate of a roof photovoltaic base structure according to an embodiment of the present invention is shown.

[0042] Figure 3 A schematic structural diagram of a groove of a roof photovoltaic base structure according to an embodiment of the present invention is shown.

[0043] Figure 4 A schematic structural diagram of a flexible single-layer roof photovoltaic system according to an embodiment of the present invention is shown.

[0044] Description of reference numerals:

[0045] 1. Prefabricated component; 1.1. First skeleton; 1.2. Thermoplastic resin layer; 2. First connecting plate; 3. Second connecting plate; 4. Groove; 5. First type steel pipe; 6. Second type steel pipe; 7. Photovoltaic panel. DETAILED DESCRIPTION

[0046] The preferred embodiments of the present invention will be described in more detail below. Although the preferred embodiments of the present invention are described below, it should be understood that the present invention can be implemented in various forms and should not be limited by the embodiments set forth herein. Instead, these embodiments are provided to make the present invention more thorough and complete and to fully convey the scope of the present invention to those skilled in the art.

[0047] like Figure 1-4 As shown, a roof photovoltaic base structure includes:

[0048] At least one preform 1, the preform 1 comprising:

[0049] The first skeleton 1.1 is in the shape of a Chinese character "几";

[0050] The thermoplastic resin layer 1.2 is arranged on the inner and outer peripheries of the first skeleton 1.1 in a conformal manner.

[0051] Specifically, the prefabricated component 1 is in the shape of a Chinese character "J" as a whole and has a certain width. It can adapt to square channel steel while increasing the connection area to avoid tearing of the waterproof layer / waterproof membrane. The first skeleton 1.1 provides support to ensure strength. The thermoplastic resin layer 1.2 is coated on the first skeleton 1.1 to protect the internal first skeleton 1.1 and is welded to the flexible single-layer roof at the same time. By utilizing the thermoplasticity of the membrane, the prefabricated component 1 can be firmly combined with the waterproof membrane through on-site hot air welding without penetrating and damaging the roof surface, and the contact of the lower end surface improves stability and wind resistance.

[0052] Furthermore, fiber mesh fabric is added to the prefabricated component 1 to improve the tensile strength of the material, disperse the load, and greatly reduce the irreversible deformation of the TPO material due to resin yielding during the stretching process, thereby improving the wind resistance of the entire photovoltaic support system.

[0053] For example, metal mesh materials can be used as reinforcement fabric solutions:

[0054] 1) Cut the stainless steel metal mesh and punch it into the “几” shape set by the preform 1 for standby use;

[0055] 2) Pickling the stainless steel mesh to remove the oil stains on the surface, immersing or spraying it with an aminosilane coupling agent for surface pretreatment, and drying it for later use;

[0056] 3) Use one-step injection molding process: place the stainless steel metal mesh part on the fixed point of the embedded part in the female mold, close the mold and then inject; the injection molding temperature is 190~230℃, and the clamping pressure is 200T~1600T.

[0057] 4) Use a two-step injection molding process: Use two sets of molds for molding. First, place the metal mesh into the injection mold, close to the inner wall of the mold. After injection molding, the metal mesh is on one side of the part. Then, place the semi-finished product from the first injection molding into the second set of molds, and perform a second injection molding to completely seal the metal mesh to obtain the final product.

[0058] For example, glass fiber and polyester fiber are used as reinforcement fabric solutions:

[0059] 1) Place glass fiber fabric or polyester fiber fabric into a "J"-shaped mold, add unsaturated polyester as a setting glue, and make a "J"-shaped reinforced fiber mesh for standby use;

[0060] 2) The subsequent injection molding scheme can be implemented with reference to the metal fabric category.

[0061] For example, nylon engineering plastics can be used as a reinforcement fabric solution:

[0062] 1) Using injection molding, a "J"-shaped fabric grid-type reinforced structural component made of nylon is produced;

[0063] 2) The prepared reinforced mesh member is then placed into a mold and injection molded as described above for the metal mesh reinforcement.

[0064] (To prevent shrinkage and deformation of the injection molded parts after molding, the injection molded parts are placed in hot water at 70-80°C for post-treatment for 1-2 hours.)

[0065] In this embodiment, a plurality of prefabricated members 1 are arranged at intervals, and at least one first connecting plate 2 is further included. Two ends of the first connecting plate 2 are respectively connected to two adjacent prefabricated members 1 .

[0066] Specifically, the first connecting plate 2 increases the contact area with the roof while ensuring the stability and connection strength of the prefabricated component 1.

[0067] In this embodiment, a plurality of prefabricated parts 1 are arranged at intervals, and further include:

[0068] At least one first connecting plate 2, with two ends of the first connecting plate 2 respectively connected to two adjacent prefabricated parts 1;

[0069] Two second connecting plates 3, which are arranged at ends of the two prefabricated parts 1 that are farthest apart from each other and are flush with the first connecting plates 2;

[0070] The first connecting plate 2 and the second connecting plate 3 have the same structure. The first connecting plate 2 includes a second frame, which is flush with the lower end of the first frame 1.1. The thermoplastic resin layer 1.2 is conformally arranged on the periphery of the first frame 1.1 and the second frame.

[0071] Specifically, adjacent prefabricated members 1 are connected by the first connecting plates 2 , and the second connecting plates 3 are used to improve the stability and connection strength of the prefabricated members 1 at both ends of the plurality of prefabricated members 1 .

[0072] In this embodiment, a groove 4 is further included. The groove 4 is provided on the lower side of the first connecting plate 2 and the second connecting plate 3 and passes directly below the preform 1 .

[0073] Specifically, the groove 4 prevents rainwater from accumulating between the prefabricated component 1 and the channel steel, facilitates drainage, and prevents the metal guide rail from being soaked in water for a long time.

[0074] In this embodiment, the width of the prefabricated component 1 is consistent with the width of the second connecting plate 3 , and the width of the first connecting plate is twice the width of the second connecting plate 2 .

[0075] Specifically, the force distribution layout saves costs while ensuring connection strength.

[0076] In this embodiment, the first frame 1.1 includes at least one of a stainless steel wire mesh frame, a stainless steel metal mesh frame, a polyester mesh cloth frame, and a nylon mesh cloth frame;

[0077] The thermoplastic resin layer 1.2 comprises at least one of a thermoplastic polyolefin layer, a polyvinyl chloride layer, and a ketone vinyl ester polymer layer.

[0078] In the embodiment, the thickness of the preform 1 is 2-10 mm, and the thermoplastic resin layer 1.2 is formed on the outer periphery of the first skeleton 1.1 by layered mold pressing or integral injection molding.

[0079] A roof photovoltaic power generation device comprises:

[0080] The roof photovoltaic pedestal structure.

[0081] In the embodiment, the roof photovoltaic pedestal structure comprises:

[0082] Two roof photovoltaic pedestal structures;

[0083] The roof photovoltaic pedestal structure comprises a plurality of preforms 1, which are arranged on the upper side of the flexible single-layer roof at intervals.

[0084] Two first steel pipes 5, which respectively pass through the plurality of preforms 1 and are parallel to each other;

[0085] A photovoltaic panel 7 is arranged on the upper side of the two first steel pipes 5 through a connecting structure.

[0086] The connecting structure comprises two second steel pipes 6 and a plurality of positioning members, the two second steel pipes 6 are arranged at the upper ends of the two first steel pipes 5 at intervals to form a cross-shaped structure, and the photovoltaic panel 7 is arranged on the upper side of the two second steel pipes 6.

[0087] Specifically, the cross-shaped frame is used to ensure the gap between the photovoltaic panel and the roof and to adapt to the adjustment of the position and posture.

[0088] A roof photovoltaic pedestal structure construction method comprises:

[0089] Adjust the hot air welding equipment to a preset air volume and temperature;

[0090] Respectively heat the lower end surface of the preform and the exposed surface of the waterproof roll to a predetermined temperature;

[0091] The heated preform and the heated exposed surface are attached to each other to be cooled and fixed, thereby forming a photovoltaic pedestal structure.

[0092] Specifically, the preforms 1 are placed at equal intervals according to the positioning and wire laying positions, the surface of the waterproof layer and the lower surface of the preform 1 should be wiped clean in advance, and the waterproof roll should be cleaned before hot air welding after being polluted or exposed to the external environment for about 7 days.

[0093] For the contaminated overlap parts of the coils, first wipe off dust and other debris with a damp cloth, then clean the welding area with clean water, and then wipe with a clean rag to remove excess water stains.

[0094] When the contamination is serious, use a special coil cleaning agent to clean it thoroughly and wipe it dry with a white rag. Wait until the coil cleaning agent is completely evaporated before welding (it takes about 15 to 30 minutes depending on the ambient temperature). The welding speed should be about 20% slower than the normal welding speed.

[0095] When using a handheld welder, the heating setting should be adjusted to the appropriate temperature for coil welding. The welding temperature and speed are determined by the ambient temperature, wind speed, and coil temperature. Before officially starting welding each day or after a sudden change in temperature, a test weld must be performed to determine the optimal welding temperature and speed.

[0096] After adjusting to the appropriate temperature, use a handheld hot air welding gun for temporary fixation to ensure that the prefabricated component 1 is installed in the correct position, and hot air weld the bottom of the prefabricated component 1 to the roof waterproof layer to fix it firmly.

[0097] In this embodiment, the peel strength between the lower end of the prefabricated component 1 and the waterproof membrane layer is greater than 4 N / mm, and the tear strength of the thermoplastic resin layer 1.2 is less than the tear strength of the waterproof membrane.

[0098] Specifically, when tearing, the thermoplastic resin layer 1.2 is damaged first, so as to ensure the integrity of the waterproof membrane and avoid water leakage.

[0099] In this embodiment, a rooftop photovoltaic base structure is used, taking processing and manufacturing as an example:

[0100] 1. Use thermoplastic materials of the same material as the roof as the material of the thermoplastic resin layer 1.2 of the base, including but not limited to thermoplastic polyolefin (TPO) waterproof membrane, polyvinyl chloride (PVC), KEE membrane, EBA membrane and other roof thermoplastic membranes. Utilizing the thermoplasticity of the membrane, the prefabricated part 1 can be firmly combined with the waterproof membrane by on-site hot air welding. Because TPO waterproof membrane has better heat resistance than other thermoplastic membranes, TPO material is more preferred as the material of the prefabricated part 1. The prefabricated part 1 is processed by injection molding. During the injection molding process, fiber mesh materials including but not limited to polyester mesh cloth, glass fiber mesh cloth, nylon mesh fabric, and metal mesh are added to increase the physical properties of the prefabricated part 1 itself, so that it can withstand the effects of roof wind loads under long-term service.

[0101] 1.1. Metal mesh is easier to shape than polyester mesh and glass fiber mesh. The dimensional stability of the product after shaping is high and the position is well maintained during the injection molding process. The preferred reinforcing fiber material is stainless steel mesh. The selected stainless steel mesh has a fiber diameter of 0.1-0.6 mm and a mesh size of 5-60.

[0102] 1.2. When using engineering plastics such as nylon as reinforcement fabric, it is necessary to first produce a "J"-shaped reinforcement fabric mesh of matching size through injection molding. The mesh count of the nylon fabric produced is 5 to 60, and the diameter of the single filament of the nylon mesh is 0.5 to 2.0 mm.

[0103] 1.3. Because polymer materials generally cannot form effective interfacial chemical bonds with materials such as metals and glass fibers, the preformed reinforcement fabric must be surface treated before production. Treatment materials include but are not limited to silane coupling agents and titanate coupling agents.

[0104] 1.4. Add titanate coupling agent to the injection molded part formula according to the coupling agent addition method and mechanism of action. Aminosilane coupling agent that can be directly sprayed or brushed on the surface of stainless steel mesh is preferred;

[0105] 2. Granulate TPO resin, pigment, additives, fillers, etc. through a twin-screw extruder to prepare exposed formula materials for later use;

[0106] 2.1 When using a bendable and shapeable metal mesh as the reinforcing fiber, the metal mesh is processed into an Ω shape by mechanical molding and used as a fixed fabric mesh for standby use; when using a polymer mesh as the reinforcing fiber, an injection molding machine is used to process nylon, polyester, etc. into an Ω-shaped reinforcing fiber through an injection molding process;

[0107] 2.2 The shaped fiber fabric is fixed in the injection molding machine mold. The TPO formula is melted by the injection molding machine and then embedded into the mold to cover the outside of the shaped mesh fabric. After pressure maintenance and shaping, the mold is opened and ejected to form the finished product.

[0108] 3. Install prefabricated parts 1

[0109] 3.1 Position and clean the roof surface of the installation location;

[0110] 3.2. Heat the prefabricated component 1 and the roof waterproofing membrane to the preset temperature and weld them together.

[0111] 4. After the prefabricated part 1 is fixed to the roof waterproofing membrane, the guide rail of the photovoltaic module is inserted into the prefabricated part 1 for fixation. The size of the raised part of the prefabricated part 1 is adapted to commonly used aluminum alloy profiles, including but not limited to (40×40mm, 41×41, 30×41mm, 50×70mm, 40×70mm rectangular guide rails). The raised part is arranged on the base in sections (including but not limited to setting any number of sections from 1 to 8). When the guide rail transfers the wind load on the photovoltaic module to the prefabricated part 1, the fixed part is subjected to stress as a whole, reducing the risk of the membrane being torn due to long-term stress.

[0112] While various embodiments of the present invention have been described above, the above description is intended to be illustrative, not exhaustive, and not limited to the disclosed embodiments. Many modifications and variations will be apparent to those skilled in the art without departing from the scope and spirit of the described embodiments.

Claims

1. A roof photovoltaic base structure, characterized in that: Comprising: At least one prefabricated part, the prefabricated part comprising: A first skeleton, in a U-shape; A thermoplastic resin layer, conformally provided on the inner and outer peripheries of the first skeleton; After the prefabricated part is fixed to the roof waterproofing membrane, the photovoltaic module guide rail is inserted into the prefabricated part in an interpenetrating manner for fixation; A plurality of the prefabricated parts are provided at intervals, and further comprising: At least one first connecting plate, the two ends of the first connecting plate are respectively connected to two adjacent prefabricated parts; Two second connecting plates, the two second connecting plates are provided at the mutually remote ends of the two prefabricated parts that are farthest apart, and are flush with the first connecting plate; The first connecting plate and the second connecting plate have the same structure, the first connecting plate includes a second skeleton, the second skeleton is flush with the lower end of the first skeleton, and the thermoplastic resin layer is conformally provided on the outer periphery of the second skeleton; Further comprising a groove, the groove is provided on the lower sides of the first connecting plate and the second connecting plate, and passes directly below the prefabricated part.

2. A rooftop photovoltaic base structure according to claim 1, characterized in that: The width of the prefabricated part is the same as the width of the second connecting plate, and the width of the first connecting plate is twice the width of the second connecting plate.

3. The structure of a roof photovoltaic base according to claim 1, wherein The first skeleton includes at least one of a stainless steel wire braided mesh skeleton, a stainless steel mesh sheet skeleton, a polyester mesh cloth skeleton, and a nylon mesh cloth skeleton; The thermoplastic resin layer includes at least one of a thermoplastic polyolefin layer, a polyvinyl chloride layer, and a ketene ester polymer layer.

4. A rooftop photovoltaic base structure according to claim 3, characterized in that: The thickness of the prefabricated part is 2 - 10 mm, and the thermoplastic resin layer is formed on the inner and outer peripheries of the first skeleton by layer-by-layer compression molding or integral injection molding.

5. A rooftop photovoltaic power generation device, characterized in that: Comprising: The structure of a roof photovoltaic base according to any one of claims 1 - 4.

6. A rooftop photovoltaic power generation device according to claim 5, characterized in that: Comprising: Two roof photovoltaic base structures; The roof photovoltaic base structure includes a plurality of prefabricated parts, and the plurality of prefabricated parts are provided at intervals on the upper side of a flexible single-layer roof; Two first-type steel pipes, respectively passing through the plurality of prefabricated parts and being parallel to each other; A photovoltaic panel, provided on the upper sides of the two first-type steel pipes through a connection structure; The connection structure includes two second-type steel pipes and a plurality of positioning parts, the two second-type steel pipes are provided at intervals and parallel to each other on the upper ends of the two first-type steel pipes to form a cross-shaped structure, and the photovoltaic panel is provided on the upper sides of the two second-type steel pipes.

7. A construction method for a rooftop photovoltaic base structure according to any one of claims 1 to 4, characterized in that: Comprising: Adjust the hot air welding equipment to a preset air volume and temperature; Respectively heat the lower end surface of the prefabricated part and the exposed surface of the waterproofing membrane to a predetermined temperature; Bond the heated prefabricated part and the heated exposed surface until they are cooled and fixed to form a photovoltaic base structure.

8. The construction method of a roof photovoltaic base structure according to claim 7, characterized in that: The welding peel strength between the lower end of the prefabricated part and the waterproofing membrane layer > 4 N / mm, and the tear strength of the thermoplastic resin layer is less than the tear strength of the waterproofing membrane.

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