A photovoltaic mounting assembly for a color steel tile roof and a manufacturing method thereof

Abstract

The application discloses a kind of photovoltaic installation components of color steel tile roof and its manufacturing method, it is related to the supporting structure field of photovoltaic module, including first clamping component, second clamping component, bolt and nut;The first clamping component is integrally formed, including first main body, the upper portion of the first main body is provided with first sliding part, middle part is provided with first cavity, lower portion is provided with first clamping part, and the inside of first sliding part is formed with installation slot;The application is slidably matched by first clamping component and second clamping component, in combination with the adjustment of connecting piece, it can be adapted to different types of color steel tile roof, without preparing multiple specifications, reduce procurement and management cost, solve the problem of poor adaptability of traditional aluminum alloy clamp fixed type and size.

Description

TECHNICAL FIELD

[0001] The present application is a kind of color steel tile roof photovoltaic installation assembly and its manufacturing method, it is related to the support structure field of photovoltaic module. BACKGROUND

[0002] In the field of color steel tile roof installation, fixture is the core component to realize the fixation of roof components (such as photovoltaic support, lightning protection device, etc.). The traditional installation fixture is mostly made of aluminum alloy, and its design and application have many limitations:

[0003] 1. The production process of aluminum alloy fixture needs to go through: aluminum ingot-aluminum profile extrusion-surface treatment-sawing-drilling-assembly. The whole process is difficult to form completely automatic production;

[0004] 2. The aluminum alloy fixture is mainly formed by extrusion process, and its structure design is limited by "one-way dimension thickening", that is, it can only increase the thickness to improve the rigidity, and cannot be realized by complex three-dimensional structure;

[0005] 3. The traditional fixture is mostly designed with fixed size, which can only adapt to color steel tiles and sizes of specific shape. Therefore, multiple sets of fixtures of different specifications need to be prepared, which increases the procurement and management cost. SUMMARY

[0006] In view of the deficiencies of the prior art, the present application aims to provide a color steel tile roof photovoltaic installation assembly and its manufacturing method to solve the problem.

[0007] In order to achieve the above-mentioned purpose, the present application is realized by the following technical scheme: a color steel tile roof photovoltaic installation assembly, comprising a first clamping component, a second clamping component, a bolt and a nut;

[0008] The first clamping component is integrally formed, comprising a first main body, the upper part of the first main body is provided with a first sliding part, the middle part is provided with a first cavity, and the lower part is provided with a first clamping part, and the inside of the first sliding part is formed with a mounting groove;

[0009] The second clamping component is integrally formed, comprising a second main body, the upper part of the second main body is provided with a second sliding part and a mounting part, the middle part is provided with a second cavity, and the lower part is provided with a second clamping part, and the inside of the second sliding part is formed with a sliding groove;

[0010] The first sliding part is slidably connected inside the sliding groove of the second sliding part, at least one of the bolts is installed along the sliding connection direction of the first sliding part and the second sliding part, the bolt is arranged through the first main body, the mounting groove and the second main body, the first main body and the second main body are locked and fixed by the bolt cooperating with the nut, at the same time, the first cavity and the second cavity are oppositely arranged to form a main cavity for accommodating the color steel tile, and the first clamping part and the second clamping part are oppositely arranged to form a clamping end for connecting the color steel tile.

[0011] Preferably, both the first clamping member and the second clamping member are formed by stamping and bending metal sheets.

[0012] Preferably, the first clamping part is a second folded edge, which is formed by bending the lower end of the metal sheet; the first sliding part consists of two U-shaped first folded edges, which are formed by bending the left and right ends of the metal sheet respectively.

[0013] Preferably, the left and right ends of the metal sheet are bent to form a third fold, the upper part of the third fold is connected to the first fold, and the lower parts of the two third folds are bent to the bottom of the second fold to form a first reinforcing end; the upper end of the metal sheet is bent to form a fourth fold, and the front end of the fourth fold abuts against the two first folds to form a second reinforcing end.

[0014] Preferably, the second clamping part is a sixth folded edge, which is formed by bending the lower end of the metal plate; the second sliding part is two U-shaped fifth folded edges, which are formed by bending the left and right ends of the metal plate respectively; the upper parts of the two fifth folded edges overlap each other to form a third reinforcing end, and the third reinforcing end is provided with at least one screw hole, thereby forming the mounting part.

[0015] Preferably, the left and right ends of the metal sheet are bent to form a seventh fold, the upper part of which is connected to the fifth fold, and the lower parts of both seventh folds are bent to the bottom of the sixth fold to form a fourth reinforcing end.

[0016] Preferably, the first clamping member has a first through hole for inserting a bolt, the bolt being located outside the first clamping member, wherein the nut is larger than the first through hole; rotating the bolt causes the nut to push the second clamping member toward the first clamping member.

[0017] A method for manufacturing a photovoltaic installation module for a color steel tile roof includes the following steps:

[0018] Step 1: Select carbon steel plates and cut them to make the first clamping component blank and the second clamping component blank;

[0019] Step 2: The blank of the first clamping component is stamped and bent to form a first clamping component having a first clamping part and a first sliding part; the blank of the second clamping component is drilled, stamped and bent to form a second clamping component having a second clamping part, a second sliding part and a mounting part.

[0020] Preferably, in step two, the first clamping component blank is stamped and bent to form a first clamping component having a first clamping part and a first sliding part. Specifically, the lower end of the first clamping component blank is stamped and bent to form a second folded edge. That is, the first clamping part is stamped and bent to both the left and right ends of the first clamping component blank to form a third folded edge and a first folded edge. The two first folded edges form a first sliding part. The lower part of the third folded edge is stamped and bent to the bottom of the second folded edge to form a first reinforcing end.

[0021] In step two, the blank of the second clamping component is stamped and bent to form a second clamping component having a second clamping part, a second sliding part, and a mounting part. Specifically, the lower end of the blank of the second clamping component is stamped and bent to form a sixth fold, that is, the first clamping part is stamped and bent to the left and right ends of the second blank to form a seventh fold and a fifth fold. The two fifth folds form a first sliding part. The lower part of the seventh fold is stamped and bent to the bottom of the second fold to form a second reinforcing end. At the same time, the upper parts of the two fifth folds overlap each other to form a third reinforcing end, and the third reinforcing end has at least one screw hole, thereby forming a mounting part.

[0022] Beneficial effects

[0023] Firstly, this invention, through the sliding fit between the first clamping component and the second clamping component, combined with the adjustment of the connecting parts, can adapt to different types of color steel tile roofs, eliminating the need to prepare multiple sets of specifications, reducing procurement and management costs, and solving the problem of poor compatibility of traditional aluminum alloy clamps in terms of fixing type and size.

[0024] Secondly, the first clamping component and the second clamping component are formed by stamping and bending metal sheets. The metal sheets are preferably 2mm carbon steel sheets. The stamping and bending process forms a horizontal and vertical reinforcing structure, so that only 2mm or even thinner carbon steel sheets are needed as the base material to meet the load-bearing capacity.

[0025] Thirdly, the production process of the first and second clamping components only requires the purchase of pre-plated carbon steel plates, which are then slitting, continuous stamping, and assembly. Throughout the process, continuous stamping can be easily fully automated, greatly improving production efficiency, reducing costs, and extending delivery time. Attached Figure Description

[0026] Other features, objects, and advantages of the present invention will become more apparent from the following detailed description of non-limiting embodiments with reference to the accompanying drawings:

[0027] Figure 1 This is a schematic diagram of the structure of a photovoltaic installation component for a color steel tile roof according to the present invention.

[0028] Figure 2 This is a schematic diagram of the structure of the first clamping member of the present invention.

[0029] Figure 3 This is a schematic diagram of the structure of the second clamping member of the present invention.

[0030] Figure 4 This is a schematic diagram of the usage state of the present invention. Figure 1 Bolts and nuts are not shown in the drawing.

[0031] Figure 5 This is a diagram illustrating the usage status of this invention. Figure 2 Bolts and nuts are not shown in the drawing. Detailed Implementation

[0032] To make the technical means, creative features, objectives and effects of this invention easier to understand, the invention will be further described below in conjunction with specific embodiments.

[0033] Please see Figures 1-3 The present invention provides a photovoltaic installation component for a color steel tile roof: including a first clamping component 1, a second clamping component 2, a bolt 31 and a nut 32;

[0034] The second clamping member 2 is integrally formed and includes a second body 23. The upper part of the second body 23 is provided with a second sliding part 21 and a mounting part 6, the middle part is provided with a second cavity S2, the lower part is provided with a second clamping part 22, and a groove B2 is formed inside the second sliding part 21.

[0035] The first sliding part 11 is slidably connected to the inside of the sliding groove B2 of the second sliding part 21. At least one bolt 31 is installed along the sliding connection direction between the first sliding part 11 and the second sliding part 21. The bolt 31 is disposed through the first body 13, the mounting groove B1 and the second body 23. The first body 13 and the second body 23 are locked by the bolt 31 and the nut 32. At the same time, the first cavity S1 and the second cavity S2 are arranged opposite to each other to form a main cavity for accommodating the color steel tile. The first clamping part 12 and the second clamping part 22 are arranged opposite to each other to form a clamping end 4 for connecting the color steel tile.

[0036] By disassembling the clamping function into two clamping components (i.e., the first clamping component 1 and the second clamping component 2) and a bolt 31 and a nut 32, dynamic clamping is achieved through sliding fit and spacing adjustment, thus solving the problem of poor adaptability of traditional fixed-size clamps. It can adapt to different types of color steel tile roofs, significantly improving its versatility. Among them, the bolt 31 passes through the two clamping components and is limited by the second clamping component 2, ensuring that the pushing force acts directly in the clamping direction, avoiding force dispersion or deviation, and making the clamping stability more stable.

[0037] The first clamping component 1 is integrally formed. Compared with welded or assembled structures, the integrally formed first clamping component 1 can eliminate connection gaps, improve overall rigidity, and avoid the risk of corrosion (color steel tile roofs are mostly exposed to the elements, so corrosion resistance is crucial). The first clamping component 1 is integrally formed and includes a first body 13. The upper part of the first body 13 is provided with a first sliding part 11, the middle part is provided with a first cavity S1, and the lower part is provided with a first clamping part 12. The first sliding part 11 has an installation groove B1 formed inside.

[0038] The first clamping part 12 is the second folded edge A2, which is formed by bending the lower end of the metal sheet; the first sliding part 11 consists of two U-shaped first folded edges A1, which are formed by bending the left and right ends of the metal sheet respectively. The mounting groove B1 serves as the sliding track with the second clamping member 2. It is naturally formed by the folded edge, without the need for additional processing of the slide rail, thereby improving material utilization and reducing process costs.

[0039] The first clamping part 12 is the second folded edge A2, which is formed by bending the lower end of the metal sheet;

[0040] The first main body 13 has a first cavity S1 in the middle, and the second main body 23 has a second cavity S2 in the middle. The first cavity S1 and the second cavity S2 are arranged opposite to each other to form a main cavity for accommodating the color steel tile. This reduces the overall weight of the component while reserving enough space for roof placement, further improving the applicability of the component to adapt to various types and sizes of color steel tile roofs in complex environments.

[0041] Furthermore, the left and right ends of the metal sheet are both bent to form a third folded edge A3. The upper part of the third folded edge A3 is connected to the first folded edge A1, and the lower parts of both third folded edges A3 are bent to the bottom of the second folded edge A2 to form a first reinforcing end C1. The third folded edge A3 wraps around the sides and bottom of the first clamping part 12, distributing the force of the first clamping part 12 to the first body 13, so as to avoid deformation of the first clamping part 12 due to excessive local stress during clamping.

[0042] The upper end of the metal sheet is bent to form a fourth folded edge A4, and the front end of the fourth folded edge A4 abuts against the two first folded edges A1 to form a second reinforcing end C2; the fourth folded edge A4 specifically solves the problem of "stress concentration" when the component is subjected to longitudinal force after installation, and avoids deformation of the first sliding part 11.

[0043] The first sliding part 11 is slidably connected to the inside of the groove B2 of the second sliding part 21. The mounting groove B1 and the groove B2 are nested to form a "double-track sliding" structure. Compared with single-track sliding, the guiding accuracy is improved, and lateral displacement during clamping is avoided.

[0044] The second sliding part 21 consists of two U-shaped fifth folded edges A5, formed by bending the left and right ends of a metal sheet, respectively. The upper parts of the two fifth folded edges A5 overlap to form a third reinforcing end C3, which has at least one screw hole (in this embodiment, there are initially two screw holes) to form the mounting part 6. This increases the upper thickness of the second sliding part 21, improving structural strength, and also provides sufficient thickness for drilling and tapping. In use, the bottom beam of the photovoltaic bracket is secured to the mounting part 6 with screws.

[0045] The second clamping part 22 is the sixth folded edge A6, which is formed by bending the lower end of the metal plate. It works with the second folded edge A2 to form a complete clamping end 4. The sixth folded edge A6 and the second folded edge A2 of the first clamping part 12 work together to form a complete clamping end 4.

[0046] The left and right ends of the metal sheet are both bent to form a seventh fold A7. The upper part of the seventh fold A7 is connected to the fifth fold A5. The lower parts of both seventh folds A7 are bent to the bottom of the sixth fold A6 to form a fourth reinforcing end C4. The fourth reinforcing end C4 is symmetrical with the first reinforcing end C1 of the first clamping part 12, which increases the overall thickness of the clamping end 4. This is used to balance the force after clamping, solve the problem of "clamping deviation" caused by traditional single-sided reinforcement, and improve clamping stability.

[0047] The inner sides of the first clamping member 1 and the second clamping member 2 are evenly distributed with a number of reinforcing ribs to avoid local stress concentration.

[0048] Preferably, the first clamping member 1 has a first through hole for inserting a bolt 31, the bolt 31 being located outside the first clamping member 1, wherein the nut 32 is larger than the first through hole; rotating the bolt 31 causes the nut 32 to push the second clamping member 2 toward the first clamping member 1, adjusting the position of the nut 32 on the bolt 31, thereby changing the maximum distance between the first clamping member 1 and the second clamping member 2.

[0049] A method for manufacturing a photovoltaic installation module for a color steel tile roof includes the following steps:

[0050] Step 1: Select a 2mm thick carbon steel plate and cut it to make the first clamping component blank and the second clamping component blank.

[0051] More specifically, taking the blank of the first clamping component as an example, the specific cutting steps are as follows: first, the carbon steel plate is cut into strips to obtain strips; then, the strips are stamped and cut according to the unfolded diagram of the first clamping component 1 to obtain the blank of the first clamping component.

[0052] Traditional clamping components often use aluminum alloys, but aluminum alloy clamps generally require a thickness of 2mm or more. Furthermore, in color steel tile clamps, aluminum alloys can only be extruded, meaning that rigidity can only be increased by increasing thickness, making it difficult to achieve complex three-dimensional structures. This invention, however, uses 2mm thick carbon steel plates to reduce material thickness while still meeting the strength requirements for clamping color steel tiles. This choice is not simply thinning, but rather based on a synergistic approach of "compensating for insufficient thickness with structural reinforcement design (such as cavities and folds)": through multiple sets of folds and cavities formed by subsequent stamping, the overall rigidity reaches industry standards, while simultaneously solving problems such as "fold cracking" and "high die wear" that easily occur during thick plate stamping.

[0053] Step 2: The blank of the first clamping component is stamped and bent to form the first clamping component 1 with the structure of the first clamping part 12 and the first sliding part 11; the blank of the second clamping component is drilled and stamped and bent to form the second clamping component 2 with the structure of the second clamping part 22, the second sliding part 21 and the mounting part 6.

[0054] Compared to welding, the one-piece molding of the mounting components in this solution can eliminate thermal deformation and weld defects, and the staged stamping process ensures the forming quality of complex structures, making it less prone to cracking compared to traditional one-time stamping.

[0055] In step two, the first clamping component blank is stamped and bent to form a first clamping component 1 with a first clamping part 12, a first sliding part 11 and other structures. Specifically, the lower end of the first clamping component blank is stamped and bent to form a second folded edge A2. That is, the first clamping part 12 is stamped and bent to both the left and right ends of the first clamping component blank to form a third folded edge A3 and a first folded edge A1. The two first folded edges A1 form the first sliding part 11. The lower part of the third folded edge A3 is stamped and bent to the bottom of the second folded edge A2 to form a first reinforcing end C1.

[0056] In step two, the blank of the second clamping component is drilled, punched and bent to form the second clamping component 2, which has a structure including a second clamping part 22, a second sliding part 21 and a mounting part 6. Specifically, the lower end of the blank of the second clamping component is punched and bent to form a sixth fold A6. That is, the first clamping part 12 punches and bends the left and right ends of the second blank to form a seventh fold A7 and a fifth fold A5. The two fifth folds A5 form the first sliding part 11. The lower part of the seventh fold A7 is punched and bent to the bottom of the second fold A2 to form a second reinforcing end C2. At the same time, the upper parts of the two fifth folds A5 overlap to form a third reinforcing end C3. The third reinforcing end C3 has at least one screw hole, thereby forming the mounting part 6.

[0057] The manufacturing method in this case involves in-depth collaborative innovation in material properties, structural requirements, and process capabilities. Through precise material selection, pre-forming cutting, and staged multi-directional stamping, it achieves progress in both lightweight and high strength, as well as compatibility between complex structures and low-cost production. It also breaks through the traditional "one-time stamping" mindset and adopts a step-by-step stamping and direction switching method to achieve non-destructive forming of complex structures.

[0058] See Figures 4-5 The present invention also provides an application of a photovoltaic installation component on a color steel tile roof, wherein the photovoltaic installation component is the photovoltaic installation component described above or an installation component prepared by the manufacturing method described above.

[0059] The foregoing has shown and described the basic principles, main features, and advantages of the present invention. It will be apparent to those skilled in the art that the invention is not limited to the details of the exemplary embodiments described above, and that the invention can be implemented in other specific forms without departing from its spirit or essential characteristics. Therefore, the embodiments should be considered illustrative and non-limiting in all respects, and the scope of the invention is defined by the appended claims rather than the foregoing description. Thus, all variations falling within the meaning and scope of equivalents of the claims are intended to be included within the scope of the invention. No reference numerals in the claims should be construed as limiting the scope of the claims.

[0060] Furthermore, it should be understood that although this specification describes embodiments, not every embodiment contains only one independent technical solution. This narrative style is merely for clarity. Those skilled in the art should consider the specification as a whole, and the technical solutions in each embodiment can also be appropriately combined to form other embodiments that can be understood by those skilled in the art.

Claims

1. A photovoltaic installation module for a color steel tile roof, characterized in that: Includes a first clamping member, a second clamping member, bolts, and nuts; The first clamping member is integrally formed and includes a first body. The upper part of the first body is provided with a first sliding part, the middle part is provided with a first cavity, the lower part is provided with a first clamping part, and the interior of the first sliding part is formed with an installation groove. The second clamping member is integrally formed and includes a second body. The upper part of the second body is provided with a second sliding part and a mounting part, the middle part is provided with a second cavity, the lower part is provided with a second clamping part, and a groove is formed inside the second sliding part. The first sliding part is slidably connected to the groove of the second sliding part. At least one bolt is installed along the sliding connection direction between the first sliding part and the second sliding part. The bolt passes through the first body, the mounting groove and the second body. The first body and the second body are locked together by the bolt and the nut. At the same time, the first cavity and the second cavity are arranged opposite to each other to form a main cavity for accommodating the color steel tile. The first clamping part and the second clamping part are arranged opposite to each other to form a clamping end for connecting the color steel tile. The first clamping part is a second folded edge, which is formed by bending the lower end of the metal sheet; the first sliding part consists of two U-shaped first folded edges, which are formed by bending the left and right ends of the metal sheet respectively. The left and right ends of the metal sheet are both bent to form a third folded edge. The upper part of the third folded edge is connected to the first folded edge. The lower parts of the two third folded edges are both bent to the bottom of the second folded edge to form a first reinforcing end. The upper end of the metal sheet is bent to form a fourth folded edge, and the front end of the fourth folded edge abuts against the two first folded edges to form a second reinforcing end. The second clamping part is a sixth folded edge, which is formed by bending the lower end of the metal plate; the second sliding part is two U-shaped fifth folded edges, which are formed by bending the left and right ends of the metal plate respectively; the upper parts of the two fifth folded edges overlap each other to form a third reinforcing end, and the third reinforcing end is provided with at least one screw hole, thereby forming the mounting part.

2. The photovoltaic installation module for a color steel tile roof according to claim 1, characterized in that: Both the first clamping component and the second clamping component are formed by stamping and bending metal sheets.

3. A photovoltaic installation module for a color steel tile roof according to claim 2, characterized in that: The left and right ends of the metal sheet are both bent to form a seventh fold. The upper part of the seventh fold is connected to the fifth fold, and the lower parts of both seventh folds are bent to the bottom of the sixth fold to form a fourth reinforcing end.

4. A photovoltaic installation module for a color steel tile roof according to claim 1, characterized in that: The first clamping member has a first through hole for inserting a bolt, the bolt being located outside the first clamping member, wherein the nut is larger than the first through hole; rotating the bolt causes the nut to push the second clamping member toward the first clamping member.

5. A method for manufacturing a photovoltaic installation module for a color steel tile roof, used to manufacture a photovoltaic installation module for a color steel tile roof as described in any one of claims 1-4, characterized in that: Includes the following steps: Step 1: Select carbon steel plates and cut them to make the first clamping component blank and the second clamping component blank; Step 2: The blank of the first clamping component is stamped and bent to form a first clamping component having a first clamping part and a first sliding part; the blank of the second clamping component is drilled, stamped and bent to form a second clamping component having a second clamping part, a second sliding part and a mounting part.

6. The method for manufacturing a photovoltaic installation component for a color steel tile roof according to claim 5, characterized in that: In step two, the blank of the first clamping component is stamped and bent to form a first clamping component having a first clamping part and a first sliding part. Specifically, the lower end of the blank of the first clamping component is stamped and bent to form a second folded edge. That is, the first clamping part is stamped and bent to the left and right ends of the blank of the first clamping component to form a third folded edge and a first folded edge. The two first folded edges form a first sliding part. The lower part of the third folded edge is stamped and bent to the bottom of the second folded edge to form a first reinforcing end. In step two, the blank of the second clamping component is stamped and bent to form a second clamping component having a second clamping part, a second sliding part, and a mounting part. Specifically, the lower end of the blank of the second clamping component is stamped and bent to form a sixth fold, that is, the first clamping part is stamped and bent to the left and right ends of the second blank to form a seventh fold and a fifth fold. The two fifth folds form a first sliding part. The lower part of the seventh fold is stamped and bent to the bottom of the second fold to form a second reinforcing end. At the same time, the upper parts of the two fifth folds overlap each other to form a third reinforcing end, and the third reinforcing end has at least one screw hole, thereby forming a mounting part.

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