Glass-free lightweight support structure for roof-mounted solar modules

Abstract

The present invention relates to a glass-free lightweight support structure for installing a solar module on a roof, which can maximize the lightweight of a solar module while enhancing the structural strength of a lightweight solar module that does not use a glass material cover to achieve lightweight. According to the present invention, as a support structure for installing a solar module on a roof, the support structure can be made lightweight by being formed of a lightweight plastic material that is excellent in mechanical strength and long-term weather resistance, and labor costs can be saved by reducing the number of workers.

Description

TECHNICAL FIELD

[0001] The present application relates to a support structure for installing a solar module on a roof, and more particularly, to a glass-free lightweight support structure for a roof-mounted solar module, which maximizes the lightweight of a solar module while enhancing the structural strength of a lightweight solar module structure without using a glass material cover to achieve lightweight. BACKGROUND

[0002] Recently, an environmentally friendly solar module using solar energy instead of fossil energy has been widely used. Since the power generation efficiency of such a solar module is proportional to the area of a light collecting panel, the economic efficiency is greatly reduced when installed on a general site, and thus is usually installed on an inclined roof of a large warehouse-type building such as a logistics warehouse or a factory to operate.

[0003] Warehouse-type buildings are usually large in scale and require insulation, and thus are constructed using a core board, which is low in construction cost. The core board has a structure formed by bonding polystyrene foam between upper and lower boards having a relatively small thickness. In addition, protrusions (mountains) and grooves (valleys) are repeatedly formed on the upper board to enhance strength and rainwater flow.

[0004] A solar module generally includes a solar cell unit, a fixed frame, a glass cover covering and protecting the front surface of the solar cell unit, a sealing material installed between the glass cover and the solar cell unit to protect the solar cell unit, a back sheet installed on the back surface of the solar cell unit to protect the solar cell unit from external environments such as heat, moisture, and ultraviolet rays, and a junction box for protecting an electric wire transmitting power generated by the solar cell unit to an inverter.

[0005] In order to install such a solar module on a roof constructed of a core board, a support structure is used. As a support structure, various structures have been proposed, but most of them are composed of a steel material having a relatively large specific gravity, and thus increase the load applied to a building such as a factory building when constructing a solar power generation system, which adversely affects the structural safety of the building.

[0006] In particular, most of the buildings (factory buildings) located in industrial complexes are old buildings constructed a long time ago, and thus have a low structural load margin. Therefore, in order to construct a large-weight photovoltaic power generation system including a support structure, the mechanical strength of the building needs to be separately reinforced, which is a major obstacle to the popularization of a solar power generation system.

[0007] Research is being conducted to reduce the fixed load of a building by lightening a solar module. In order to reduce the weight of the solar module, a glass cover having a relatively large specific gravity needs to be replaced with a lightweight material or reduced in thickness. If a thin film form material is used instead of the glass cover, the weight of the solar module can be reduced by 50%. However, due to reasons on the characteristics of the thin film material, there are limitations in securing the mechanical strength of the solar module.

[0008]

Prior Art Documents

[0009]

Patent Documents

[0010] KR 10-2322379B1, 2021.11.01.

[0011] KR 10-2342496B1, 2021.12.20. SUMMARY

[0012]

Technical Problems

[0013] Accordingly, the present application aims to provide a glass-free type lightened support structure for a roof-mounted solar module that secures the mechanical strength of a glass-free type solar module that does not use a glass cover and can be applied in the field.

[0014] In addition, the present application can be proposed in order to individually achieve the foregoing objects or a combination of these objects, in addition, is not limited to these objects, and can further provide more objects in addition thereto through the description of the embodiments and claims to be described later.

[0015]

Technical Solution

[0016] To achieve the above object, an embodiment of the present application provides a glass-free lightweight support structure for a roof-mounted solar module, which is used to mount a lightweight solar module on a roof of a building, the solar module including a solar cell unit that converts solar energy into electric energy, a thin film that covers and protects a front surface of the solar cell unit, and a back sheet that protects a back surface of the solar cell unit, wherein the glass-free lightweight support structure for the roof-mounted solar module includes: first and second support plates made of a plastic material and configured in a "mouth" shape, with extension pieces formed at outer edges to have a staggered layer upward and downward and extend outward, and a plurality of reinforcing rods formed in a central portion in parallel to support a lower portion of the solar module; a catch portion and a coupling portion that connect the first and second support plates to each other in a snap connection manner through connection holes respectively formed at both longitudinal end portions of the first and second support plates; and horizontal and vertical frames installed at the extension pieces of the first and second support plates to fix outer edges of the solar module placed at upper portions of the first and second support plates to the first and second support plates.

[0017] In addition, the catch portion can include a catch plate having a press protrusion formed at a central portion of a lower portion to press a connection portion of the first and second support plates, and a pair of catch hooks respectively formed at left and right sides of the catch plate with the press protrusion as a center to penetrate the connection holes respectively formed at the first and second support plates.

[0018] In addition, the coupling portion can include a coupling plate arranged in parallel to the catch plate with a connection portion of the first and second support plates as a boundary, and a pair of hanging groove portions formed in parallel at an upper portion of the coupling plate to have a catch edge for hanging after the pair of catch hooks penetrating the connection holes are inserted.

[0019] In addition, the horizontal frame can include first and second support tube portions made of a tube shape having a "mouth" cross section and formed to be spaced apart from each other, and a connection portion that connects upper portions of the first and second support tube portions and forms a hanging strip extending along an outer side of the second support tube portion for insertion of a lateral side outer edge of the solar module.

[0020] In addition, the longitudinal frame can include a third support pipe portion formed in a pipe shape having a "mouth" shape in cross section, an extension support portion formed to extend horizontally outward from a lower portion of one side of the third support pipe portion to support the extension piece, and a hanging strip formed to extend inward from an upper portion of the other side of the third support pipe portion in a direction opposite to the extension direction of the extension support portion, for insertion of the outer edge of the longitudinal side of the solar module.

[0021] In addition, the back plate can be formed of an aluminum-zinc alloy plated material and formed with a plurality of holes in a plurality of rows and columns to achieve light weight.

[0022] In addition, a reinforcing plate can be further included to be installed between the solar module and the first and second support plates, and the reinforcing plate can be formed of an aluminum-zinc alloy plated material and formed with a plurality of holes in a plurality of rows and columns to achieve light weight.

[0023]

Effects of Invention

[0024] As described above, according to the present application, by forming a support structure for installing a solar module on a roof using a light weight plastic material having excellent mechanical strength and long-term weather resistance, the effect of saving labor cost can be achieved by achieving light weight of the support structure and reducing the number of workers.

[0025] In addition, according to the present application, by connecting a plurality of support plates formed of a light weight plastic material using a snap coupling method based on a catch portion and a coupling portion, and expanding the array of solar modules simply, the construction time can be shortened.

[0026] In addition, according to the present application, by further installing a back plate formed of an aluminum-zinc alloy plated material and formed with a plurality of holes at the lower portion of the solar cell unit, the structural strength (mechanical strength) of the light weight solar module can be strengthened while achieving light weight.

[0027] In addition, according to the present application, by forming a support structure for installing a solar module on a roof using a light weight plastic material having excellent mechanical strength and long-term weather resistance, the effect of saving labor cost can be achieved by achieving light weight of the support structure and reducing the number of workers. BRIEF DESCRIPTION OF DRAWINGS

[0028] Figure 1 FIG. 1 is a view showing a support structure for a solar module installed on a roof according to an embodiment of the present application.

[0029] Figure 2 FIG. 2 is a view showing the support structure for a solar module installed on a roof according to the embodiment of the present application, viewed from below. Figure 1 FIG. 3 is a view showing the support structure for a solar module installed on a roof according to the embodiment of the present application, viewed from above.

[0030] Figure 3is a sectional view showing one example of a solar module of the present application.

[0031] Figure 4 is a plan view showing Figure 3 a back sheet shown in FIG. 1.

[0032] Figure 5 is a plan view showing Figure 1 a first support sheet and a second support sheet shown in FIG. 1.

[0033] Figure 6 is a view showing a part of Figure 5 the first support sheet and the second support sheet shown in FIG. 1.

[0034] Figure 7 is a view showing a ratchet portion of one example of the present application.

[0035] Figure 8 is a view showing a joint portion of one example of the present application.

[0036] Figure 9 is a sectional view showing Figure 1 the horizontal frame and the vertical frame shown in FIG. 1. DETAILED DESCRIPTION

[0037] Hereinafter, the advantages and features of the present application and a method of achieving them will become more apparent from the following embodiments described in detail in conjunction with the accompanying drawings. Throughout the specification, the same reference numerals refer to the same constituent elements. In addition, when described as "A and / or B", it can mean all of A and B, or either one of A or B. In addition, the size and the shape of each constituent element shown in each drawing can be exaggerated for the convenience of description, and are not intended to be limiting.

[0038] Hereinafter, the advantages and features of the present application and a method of achieving them will become more apparent from the following embodiments described in detail in conjunction with the accompanying drawings. Throughout the specification, the same reference numerals refer to the same constituent elements. In addition, when described as "A and / or B", it can mean all of A and B, or either one of A or B. In addition, the size and the shape of each constituent element shown in each drawing can be exaggerated for the convenience of description, and are not intended to be limiting.

[0039] Figure 1 is a view briefly showing a support structure for a roof-mounted solar module of an embodiment of the present application, Figure 2 is a view showing Figure 1 a support structure for a roof-mounted solar module shown in FIG. 1, for the convenience of description, the solar module is omitted.

[0040] Referring to Figure 1 and Figure 2 , a support structure 10 for a roof-mounted solar module of an embodiment of the present application, as a structure for mounting a solar module, includes a first support sheet 11 and a second support sheet 12 composed of a plastic material and supporting a lower portion of the solar module.

[0041] Figure 3 is a sectional view showing one example of a solar module of the present application.

[0042] Referring to Figure 3 , in order to achieve weight reduction, a solar module 1 according to an example of the present invention uses a thin film 1b to protect the front and / or back of a solar cell unit 1a, instead of using a glass cover to cover and protect the front of the solar cell unit 1a. At this time, the thin film 1b can be, for example, a sealing material made of ethylene vinyl acetate (EVA).

[0043] Moreover, since the glass cover is omitted, a backsheet 1c is installed to strengthen the structural strength of the solar module 1. The backsheet 1c is installed below the thin film 1b attached to the back of the solar cell unit 1a to strengthen the mechanical strength of the solar cell unit 1a. On the other hand, it protects the solar cell unit 1a from external environments such as heat, moisture, and ultraviolet rays.

[0044] At the outer edge of the solar module 1, for example, at the outer edge of the mutually stacked solar cell unit 1a, thin film 1b, and backsheet 1c, a fixing frame 1d is installed. In addition, a junction box (not shown) can be installed to protect the wires that transmit the power generated by the solar cell unit 1b to the inverter.

[0045] Figure 4 is a schematic top view showing Figure 3 the backsheet shown.

[0046] As Figure 4 shown, the backsheet 1c of the present invention can be made of, for example, an aluminum-zinc alloy plating material. For weight reduction, a plurality of holes h can be formed in a multi-row and multi-column manner overall.

[0047] As the aluminum-zinc alloy plating material, a gold-plated steel sheet made of aluminum and zinc is used. In addition, in order to simultaneously meet the structural strength and weight reduction of the solar module 1, the plurality of holes h can account for more than 50% of the total area of the backsheet 1c, and preferably, can account for 70%-80%.

[0048] Figure 5 is a schematic diagram showing Figure 1 the first support plate and the second support plate shown. (a) is a view of the first support plate and the second support plate observed from above, and (b) is a view observed from below.

[0049] As Figures 1 to 5 shown, the first support plate 11 and the second support plate 12 can be formed of the same structure as each other. For example, the first support plate 11 and the second support plate 12 are each formed in a "square" shape, and extension pieces 111, 121 with stepped layers t up and down and extending outward are formed on their outer edges. Moreover, in order to achieve weight reduction, a hollow is provided in the center, and in order to divide the hollow, a plurality of reinforcing bars 112, 122 are arranged side by side.

[0050] Figure 6 is an enlarged view showing Figure 5 a part of the first support plate and the second support plate shown, (a) is an enlarged view showing Figure 4 the "A" part of, (B) is an enlarged view showing Figure 4 the "B" part of.

[0051] As shown in Figure 5 and Figure 6 the extension pieces 111, 121 can be formed to extend in a "匚" shape on three of the four faces of the first support plate 11 and the second support plate 12 formed in a "口" shape. And a plurality of connecting holes 111a, 121a are formed for passing through and combining fasteners such as screws for connecting and fixing the first support plate 11 and the second support plate 12 to the sandwich panel roof.

[0052] In addition, as shown in Figure 5 connecting holes 111b, 121b are respectively formed at both longitudinal end portions of the extension pieces 111, 121, and the connecting holes 111b, 121b are used to connect the adjacent first support plate 11 and second support plate 12 to each other. At this time, the connecting holes 111b, 121b can be formed in a rectangular or square hole structure.

[0053] In the first support plate 11 and the second support plate 12, since both longitudinal end portions of the extension pieces 111, 121 are formed in a manner having a stepped difference t, even if one end portion is arranged with the upper and lower portions overlapping each other in order to connect the first support plate 11 and the second support plate 12 to each other, there is no stepped difference in the up and down directions (refer to Figure 1 ) and a horizontal plane can be formed. Thus, it can be stably connected and fixed to the protrusion of the sandwich panel roof.

[0054] As shown in Figure 1 and Figure 5 the first support plate 11 and the second support plate 12 can be connected to each other in a snap connection manner between a set of adjacent configurations through the connecting holes 111b, 121b.

[0055] As an example for implementing the snap connection manner, a tooth portion 13 and a coupling portion 14 are proposed.

[0056] Figure 7 is a diagram briefly showing a tooth portion of an example of the present invention, Figure 8 is a diagram briefly showing a coupling portion of an example of the present invention, (a) is a view observed from above, (b) is a view observed from below, (c) is a view observed from the front.

[0057] Refer to Figure 7The latch portion 13 includes a latch plate 131 formed with a pressurizing protrusion 131a for pressurizing the connection portions of the first support plate 11 and the second support plate 12 downward, and a pair of latches 132 formed on the left and right sides of the latch plate 131 with the pressurizing protrusion 131a as the center, which penetrate the connection holes 111b, 121b formed in the first support plate 11 and the second support plate 12.

[0058] Referring to Figure 8 , the coupling portion 14 for fixing the latch portion 13 includes a coupling plate 141 disposed on the lower side of the connection portions of the first support plate 11 and the second support plate 12, and a pair of hooking groove portions 142 formed on the upper portion of the coupling plate 141 in parallel, which are formed with latch edges 142a for hooking upward after the pair of latches 132 penetrating the connection holes 111b, 121b are inserted.

[0059] As shown in Figure 1 and Figure 2 , the latch portion 13 is disposed on the upper side (or the lower side) of the connection portions of the first support plate 11 and the second support plate 12, and the coupling portion 14 is disposed on the lower side (or the upper side) of the connection portions of the first support plate 11 and the second support plate 12 so as to be aligned with the latch portion 13 upward and downward. In this state, the pair of latches 132 penetrating the connection holes 111b, 121b are inserted into the pair of hooking groove portions 142 formed in the coupling portion 14. The pair of latches 132 penetrating the connection holes 111b, 121b are hooked to the latch edges 142a formed in the hooking groove portions 142 in the separating direction. Thus, the first support plate 11 and the second support plate 12 are connected to each other by the latch portion 13 and the coupling portion 14.

[0060] On the other hand, in order to fix the solar module 1 placed on the upper sides of the first support plate 11 and the second support plate 12 to the first support plate 11 and the second support plate 12, the horizontal frame 15 and the vertical frame 16 are installed.

[0061] In Figure 1 , for convenience of description, the horizontal frame 15 and the vertical frame 16 are installed only on one side of the lateral side and the longitudinal side of the first support plate 11 and the second support plate 12 connected by the latch portion 13 and the coupling portion 14, but in fact, the horizontal frame 15 and the vertical frame 16 are installed on both sides of the lateral side and the longitudinal side of the first support plate 11 and the second support plate 12 connected to each other, respectively.

[0062] Figure 9 is a width direction sectional view briefly showing the horizontal frame and the vertical frame shown in Figure 1 , (a) is a sectional view of the horizontal frame, and (b) is a sectional view of the vertical frame.

[0063] As shown in Figure 1As shown, the horizontal frame 15 is connected and fixed to the upper lateral side of the extension pieces 111 and 121 of the first support plate 11 and the second support plate 12, which are connected to each other, by fasteners such as screws.

[0064] like Figure 9 As shown in (a), the horizontal frame 15 includes: a first support tube 151 and a second support tube 152, which are supported on the upper surface of the extension pieces 111 and 121 of the first support plate 11 and the second support plate 12, respectively, and are formed in a "U"-shaped cross section and are spaced apart from each other; a connecting part 153, which connects the upper parts of the first support tube 151 and the second support tube 152 to each other, and extends outward from the second support tube 152 to form a hanging strip 153a for the outer edge of the lateral side of the solar module 1 (the lateral side of the fixing frame 1d) to be inserted.

[0065] like Figure 1 As shown, the longitudinal frame 16 is connected and fixed to the upper longitudinal side of the extension pieces 111 and 121 of the first support plate 11 and the second support plate 12, which are connected to each other, by fasteners such as screws.

[0066] Vertical frame 16 Figure 9 As shown in (b), it includes: a third support tube 161, which is supported on the upper surface of the extension pieces 111 and 121 of the first support plate 11 and the second support plate 12, and has a cross-section in the shape of a "U"; an extension support 162, which extends horizontally outward from the lower part of one side of the third support tube 161 and is supported on the first support plate 11 and the second support plate 12; and a hook strip 163, which extends inward from the upper part of the other side of the third support tube 161 in the opposite direction to the extension direction of the extension support 162, for insertion into the longitudinal outer edge of the solar module 1 (the longitudinal side of the fixing frame 1d).

[0067] Similar to the first support plate 11 and the second support plate 12, the horizontal frame 15 and the vertical frame 16 can be formed of lightweight plastic and are connected and fixed to the first support plate 11 and the second support plate 12 by fasteners such as screws. Alternatively, the solar module 1 can also be connected and fixed by the fasteners while in conjunction with the horizontal frame 15 and the vertical frame 16.

[0068] On the other hand, to enhance the structural strength of the solar module 1, a reinforcing plate (not shown) made of an aluminum-zinc alloy coating material can be formed between the solar module 1 and the first support plate 11 and the second support plate 12. When the reinforcing plate is further applied, a thin film can be used instead of the aluminum-zinc alloy coating material for the back plate 1c. Additionally, the reinforcing plate can be used in conjunction with... Figure 4 The backplate 1c shown has the same shape. That is, it can be formed with multiple holes for the purpose of weight reduction.

[0069] In view of the foregoing, the preferred embodiments of the present application have been described and illustrated using specific terms, but these terms are only used to clearly describe the present application. Furthermore, it is obvious that the embodiments of the present application and the described terms can be applied to various modifications and changes without exceeding the technical idea and scope of the following claims. Such modified embodiments should not be interpreted independently of the idea and scope of the present application, but should be construed as falling within the claims of the present application.

[0070] Reference numerals

[0071] 1: solar module 1a: solar cell unit

[0072] 1b: thin film 1c: back sheet

[0073] 1d: fixing frame 10: support structure

[0074] 11: first support plate 12: second support plate

[0075] 13: engagement portion 14: coupling portion

[0076] 15: horizontal frame 16: vertical frame

[0077] 111, 121: extension piece 111a, 121a: coupling hole

[0078] 111b, 121b: connection hole 112, 122: reinforcing rod

[0079] 131: engagement plate 131a: pressurizing protrusion

[0080] 132: hook 141: coupling plate

[0081] 142: hooking groove portion 142a: hooking strip

[0082] 151: first support pipe portion 152: second support pipe portion

[0083] 153: connection portion 153a: engagement rib

[0084] 161: third support pipe portion 162: extension support portion

[0085] 163: hooking strip h: hole

[0086] t: staggered layer

Claims

1. A glass-free type light-weight support structure for mounting a solar module on a roof, the support structure for mounting a light-weight solar module on a roof of a building, the solar module including a solar cell unit converting solar energy into electric energy, a thin film covering and protecting a front face of the solar cell unit, and a back sheet protecting a back face of the solar cell unit, wherein, The non-glass type light-weight support structure for a roof-mounted solar module includes: first and second support plates made of a plastic material and formed in a "mouth" shape with extension pieces formed at outer edges and having staggered layers upward and outward, and a plurality of reinforcing rods formed side by side at a center to support a lower portion of the solar module; a catch portion and a coupling portion that connect the first and second support plates to each other in a snap connection manner through connection holes formed at both longitudinal end portions of the first and second support plates; and horizontal and vertical frames installed at the extension pieces of the first and second support plates to fix outer edges of the solar module placed at upper portions of the first and second support plates to the first and second support plates.

2. The non-glass type light-weight support structure for a roof-mounted solar module according to claim 1, wherein the catch portion includes a catch plate having a press protrusion formed at a center of a lower portion to press a connection portion of the first and second support plates, and a pair of catch hooks formed at left and right sides of the catch plate with the press protrusion as a center to penetrate the connection holes formed at the first and second support plates.

3. The non-glass type light-weight support structure for a roof-mounted solar module according to claim 2, wherein the coupling portion includes a coupling plate disposed side by side with the catch plate with a connection portion of the first and second support plates as a boundary, and a pair of hooking groove portions formed side by side at an upper portion of the coupling plate to form a catch edge for hooking after the pair of catch hooks penetrating the connection holes are inserted.

4. The non-glass type light-weight support structure for a roof-mounted solar module according to claim 1, wherein the horizontal frame includes first and second support pipe portions formed in a pipe shape with a "mouth" cross section and spaced apart from each other, and a connection portion that connects upper portions of the first and second support pipe portions and forms a hooking strip extending along an outer side of the second support pipe portion for insertion of a longitudinal side outer edge of the solar module.

5. The non-glass type light-weight support structure for a roof-mounted solar module according to claim 4, wherein the vertical frame includes a third support pipe portion formed in a pipe shape with a "mouth" cross section, an extension support portion horizontally extending outward from a lower portion of one side of the third support pipe portion to support the extension piece, and a hooking strip extending inward from an upper portion of the other side of the third support pipe portion in a direction opposite to an extension direction of the extension support portion for insertion of the longitudinal side outer edge of the solar module.

6. The non-glass type light-weight support structure for a roof-mounted solar module according to claim 1, wherein The back plate is made of an aluminum-zinc alloy plated material and has a plurality of holes formed in a plurality of rows and columns to achieve light weight.

7. The glass-free, light-weight support structure for a solar module installed on a roof according to claim 1, wherein, A reinforcing plate is further included between the solar module and the first and second support plates, and the reinforcing plate is made of an aluminum-zinc alloy plated material and has a plurality of holes formed in a plurality of rows and columns to achieve light weight.

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