Trestle for solar panel, manufacturing method therefor, and installation method for solar panel

Abstract

To easily support a load including a solar panel by the structure of a building.SOLUTION: A trestle 1 has a frame body supporting a solar panel set. The frame body extends linearly to straddle a plurality of solar panel sets arranged in a right-left direction, and is so arranged as to straddle two adjacent beams. A filler is charged in C-shaped steel of a frame member 300 of the frame body. The filler is preferably mortar. Further, it is preferable that reinforcing bars are embedded in the filler and a binder material is included.SELECTED DRAWING: Figure 4

Description

[Technical field]

[0001] The present invention relates to a stand for mounting solar panels, a manufacturing method thereof, and a method for mounting solar panels. [Background technology]

[0002] Conventionally, mounting frames have been used to install solar panels on the rooftops of buildings. The fixed frame described in Patent Document 1 is one example of such a mounting frame, in which the solar panel is installed on the rooftop by inserting it into a slide groove of the fixed frame fixed to the rooftop. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Patent No. 7278460 Summary of the Invention [Problem to be solved by the invention]

[0004] The inventor noticed that when solar panels are installed on a rooftop, sufficient consideration is not always given to whether the building structure supporting the rooftop can withstand the load of the solar panels and their mountings.

[0005] An object of the present invention is to provide a solar panel stand that enables a load including a solar panel to be easily supported by a building structure, a manufacturing method thereof, and a method for installing a solar panel. [Means for solving the problem]

[0006] The solar panel mounting of the present invention comprises a frame body that supports solar panels on the rooftop of a building, the frame body extending in a straight line so as to span a plurality of the solar panels arranged horizontally, and the frame body is filled with solidified filler material.

[0007] According to conventional solar panel installation methods, as shown in the above-mentioned Patent Document 1, for example, a fixing frame is installed for each solar panel. Therefore, the load from the solar panel and the fixing frame is likely to be generated locally on the rooftop structure. In contrast, the frame of the present invention extends across multiple solar panels, so the load is more easily distributed than in the conventional technology.

[0008] On the other hand, if the frame is long, the load of the solar panel causes deformation such as bending of the frame, which causes the frame to come into contact with the rooftop in a localized area, and the load of the solar panel and the mounting frame may be concentrated there. In response to this, the frame of the present invention is filled with a filler. This increases the strength of the frame. Therefore, deformation of the frame is suppressed, and the concentration of the load due to deformation of the frame is suppressed.

[0009] As a result of the above, the mounting frame of the present invention makes it easy for the building structure to support the load including the solar panel.

[0010] In the present invention, the filler is preferably mortar. If concrete is used, there is a risk that the aggregate will be unevenly distributed, resulting in uneven strength. By using mortar, such uneven strength can be suppressed.

[0011] In the present invention, it is preferable that the filler contains a binder material that improves the strength of the filler, thereby improving the strength of the entire frame.

[0012] In the present invention, it is preferable that the frame has a rectangular shape in a cross section perpendicular to its length direction, and an opening extending in the length direction is formed in either a top wall or a bottom wall of the frame, whereby moisture within the frame can be released to the outside of the frame through the opening, thereby suppressing damage to the frame due to freezing of moisture within the frame or corrosion of the frame.

[0013] In the present invention, it is preferable that a protrusion is formed in the side wall of the frame body so as to protrude toward the opening in the width direction of the frame body, thereby preventing the entire or part of the filler inside from escaping from the frame body.

[0014] In addition, the present invention further includes a reinforcing bar embedded in the filling material and a support material that supports the reinforcing bar within the filling material, and the support material extends along the width direction of the frame body, and both ends of the support material in the width direction of the frame body are preferably in contact with the inner surface of one side wall of the frame body and the inner surface of the other side wall of the frame body, respectively. This allows the reinforcing bar to improve the strength of the entire frame body. Also, the support material can be made to properly support the reinforcing bar.

[0015] In the present invention, it is preferable that a through hole is formed in each of the one side wall and the other side wall, the through hole is opened at each of both ends of the support material, a recess is formed in the support material facing the through hole in the width direction of the frame body, and a screw thread is formed in the recess. According to this, when filling the frame body with a filler during the manufacture of the rack, the support material can be appropriately supported by a screw member such as a bolt through the through hole from the outside of the frame body. The screw member used at this time may be removed from the frame body after the filled filler material has solidified, or may be left attached to the frame body.

[0016] In addition, in the present invention, it is preferable that the frame body has a plurality of frame members extending in its length direction and a connecting member that connects the plurality of frame members to each other in the length direction, the connecting member has a long through hole in the length direction, and the connecting member is fixed to the frame member by fastening a screw member that passes through the through hole of the connecting member to the frame member. In this way, the length of the entire frame body can be secured by connecting the frame members. Also, when attaching the connecting member to the frame member with the screw member through the through hole, the attachment position can be adjusted because the through hole is long.

[0017] In the present invention, it is preferable that at least a part of the upper surface of the connecting member is along a plane inclined with respect to a horizontal plane, and the solar panel is disposed along the inclined plane and fixed to the part of the upper surface of the connecting member. In this way, the solar panel can be installed on the rack while being inclined along the upper surface of the connecting member.

[0018] The manufacturing method for a solar panel mount according to the present invention includes an arrangement step of arranging the support material within the frame body so that the recess of the support material faces the through hole in the width direction of the frame body, an insertion step of inserting a screw member from outside the frame body through the through hole into the recess of the support material after the arrangement step, a filling step of filling the frame body with the filler material before solidification after the insertion step, and a solidification step of solidifying the filler material within the frame body after the filling step.

[0019] For example, instead of using the support material of the present invention, a relatively long screw shaft may be inserted through the frame in the width direction, and nuts may be attached to the bolts from both sides to be tightened. However, this method may cause damage to the frame and the filler inside by tightening the nuts from both sides. In contrast, the manufacturing method using the support material of the present invention does not cause damage due to tightening.

[0020] In the method for installing solar panels using the solar panel mount according to the present invention, the frame is disposed so as to straddle beams of two adjacent buildings that support a rooftop structure.

[0021] According to this, by using the frame of the present invention, not only can the load be distributed, but also the load can be appropriately supported by the two beams. [Brief description of the drawings]

[0022] [Figure 1] FIG. 1 is a front view of a solar panel stand according to an embodiment of the present invention. [Diagram 2] FIG. 2 is a plan view of a portion of the solar panel stand of FIG. 1. [Diagram 3] 3 is a cross-sectional view (including a partial end view) of the solar panel stand taken along line III-III' in FIG. 1. [Figure 4] FIG. 2 is an enlarged view of the area surrounded by the dashed dotted line IV in FIG. [Diagram 5] 2 is an enlarged view of the area surrounded by the dashed dotted line V in FIG. [Figure 6] 2 is a flowchart showing a method for manufacturing the solar panel stand of FIG. 1. [Figure 7] 1. FIG. 4 is a cross-sectional view (including a partial end view) of a frame according to a modified example of the embodiment in FIG. [Figure 8] 1. FIG. 4 is a schematic diagram showing a solar panel and a left connecting member according to a modified example of the embodiment in FIG. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0023] Hereinafter, a solar panel stand 1 (hereinafter referred to as the stand 1) according to one embodiment of the present invention will be described with reference to Figs. 1 to 5. The stand 1 is a stand that supports a solar panel set 500 installed on the rooftop of a building. The solar panel set 500 has a left solar panel 510 and a right solar panel 520. A plurality of solar panel sets 500 are installed side by side along the left-right direction and the front-rear direction, with the right end of the left solar panel 510 and the left end of the right solar panel 520 connected to each other. In the following, as shown in Figs. 1 and 2, the up-down direction of the rooftop of the building on which the stand 1 is installed is referred to as the up-down direction, the lateral direction of the stand 1 is referred to as the left-right direction, and the direction perpendicular to the up-down direction and the left-right direction is referred to as the front-rear direction.

[0024] As shown in Fig. 1, the mounting base 1 has a frame body 100 and a panel connection structure 200. As shown in Fig. 2, the frame body 100 extends linearly so as to straddle a plurality of solar panel sets 500 in the left-right direction.

[0025] The frame body 100 has a plurality of frame members 300 and a frame body connecting structure 400. The plurality of frame members 300 are arranged in a row along the left-right direction as shown in FIG. 1 and FIG. 2. As shown in FIG. 2, each frame member 300 straddles the entire solar panel set 500 consisting of a left solar panel 510 and a right solar panel 520 in the left-right direction. The frame body 100 supports the solar panel set 500 at each of the front end and the rear end of the solar panel set 500. The frame body 100 has a plurality of frame members 300 and a frame body connecting structure 400. The plurality of frame members 300 are installed at each of the front end and the rear end of the solar panel set 500 in a state where they are connected to each other along the left-right direction by the frame body connecting structure 400. Details of such a connecting structure of the frame members 300 and a supporting structure of the solar panel set 500 will be described below.

[0026] As shown in FIG. 3, each frame member 300 has a C-shaped steel 310, a support material 320, a reinforcing bar 330, and a filler 340. As shown in FIG. 3 and FIG. 4, the C-shaped steel 310 extends in the left-right direction and has a rectangular shape in a cross section perpendicular to the left-right direction. The C-shaped steel 310 has a left-right symmetrical structure. The C-shaped steel 310 has a ceiling wall 311, a bottom wall 312, a front wall 313, and a rear wall 314. The ceiling wall 311 has a front protruding portion 311a and a rear protruding portion 311b. The front protruding portion 311a protrudes from the entire upper end portion of the front wall 313 toward the rear protruding portion 311b. The rear protruding portion 311b protrudes from the entire upper end portion of the rear wall 314 toward the front protruding portion 311a. The front protruding portion 311a and the rear protruding portion 311b protrude toward each other. The ceiling wall 311 has an opening 311c formed therein, which extends in the left-right direction from the left end to the right end.

[0027] As shown in FIG. 4, through holes 313a and 313b are formed at the right end of the front wall 313 at equal intervals in the left-right direction. Similarly, two through holes including through hole 314b (see FIG. 3) are formed at the right end of the rear wall 314. Through hole 313b and through hole 314b face each other. The other through holes of the front wall 313 and the rear wall 314 also face each other in the front-rear direction. Similarly, two through holes are formed at the left end of the front wall 313. Two through holes are formed at the left end of the rear wall 314. The two through holes at the left end of the front wall 313 and the two through holes at the left end of the rear wall 314 face each other in the front-rear direction.

[0028] As shown in FIG. 3, the support member 320 is a member extending in the front-rear direction inside the C-shaped steel 310. The length of the support member 320 is the same as the length of the internal space of the C-shaped steel 310 in the front-rear direction. The support member 320 has a round pipe 321 and nuts 322a and 322b. The nut 322a is connected to the front end of the round pipe 321. The nut 322b is connected to the rear end of the round pipe 321. The support member 320 is installed between the through holes 313b and 314b. The front end of the nut 322a is in contact with the inner surface of the front wall 313. The rear end of the nut 322b is in contact with the inner surface of the rear wall 314. Similarly, support material 320 is installed between through hole 313a of front wall 313 and other through holes of rear wall 314, with the front end of support material 320 in contact with the inner surface of front wall 313 and the rear end of support material 320 in contact with the inner surface of rear wall 314. Similarly, support material 320 is installed between two through holes at the left end of front wall 313 and two through holes at the left end of rear wall 314.

[0029] The reinforcing bar 330 has steel bars 331 and 332. The bars 331 and 332 are members extending along the left-right direction of the C-shaped steel 310. The left-right length of the bars 331 and 332 is the same as the left-right length of the internal space of the C-shaped steel 310. The bars 331 and 332 are arranged parallel to each other inside the C-shaped steel 310. The bars 331 and 332 are placed on the support material 320. The bars 331 and 332 are supported by the support material 320. The reinforcing bar 330 may include one bar or three or more bars.

[0030] The filler 340 is filled inside the C-shaped steel 310 in an area spanning the solar panel set 500 in the left-right direction. Mortar, concrete, or the like may be used for the filler 340, with mortar being preferred. A binder material may be used for the filler 340. The binder material may be glass fiber, sand, gravel, or the like.

[0031] 4, the frame body connecting structure 400 is a member that connects two adjacent frame members 300 in the left-right direction. The frame body connecting structure 400 has left and right connecting members 410 (connecting members in the present invention) and front and rear connecting members 450.

[0032] The left and right connecting members 410 have a left connecting member 420, a right connecting member 430, and an intermediate connecting member 440. As shown in Figures 3 and 4, the left connecting member 420 extends in the left-right direction and has a roughly rectangular shape in a cross section perpendicular to the left-right direction. The left connecting member 420 is a U-shaped member that opens downward. The left connecting member 420 has a ceiling wall 421, a front wall 422, and a rear wall 423.

[0033] As shown in FIG. 4, the upper surface of the ceiling wall 421 is along a plane that is inclined downward from left to right with respect to the horizontal plane. The ceiling wall 421 has a through hole 421a for fixing the right solar panel 520. The inner surfaces of the front wall 422 and the rear wall 433 are in contact with the outer surfaces of the front wall 313 and the rear wall 314 of the frame member 300, respectively. The right end of the front wall 422 is formed with through holes 422a, 422b, and 422c at equal intervals in the left-right direction. The through holes 422a, 422b, and 422c are each a hole that is elongated in the left-right direction. Similarly, the right end of the rear wall 423 is formed with three through holes including the through hole 423b (see FIG. 3) at equal intervals in the left-right direction. The three through holes are each a hole that is elongated in the left-right direction. The through hole 422b and the through hole 423b face each other. The other through holes in the front wall 422 and the rear wall 423 are similarly opposed to each other in the front-rear direction.

[0034] As shown in Fig. 3, the through hole 313b of the front wall 313 of the C-shaped steel 310 and the through hole 422b of the front wall 422 of the left connecting member 420 face each other in the front-rear direction. The position of the through hole 422b relative to the through hole 313b is adjusted by moving the left connecting member 420 left and right relative to the C-shaped steel 310. A bolt 461 (a screw member in the present invention) that passes through the through hole 422b passes through the through hole 313b, and while sandwiching the C-shaped steel 310 and the left connecting member 420 between the nut 322a of the support member 320, it is tightened to the screw thread of the nut 322a. Similarly, the through hole 314b of the rear wall 314 of the C-shaped steel 310 and the through hole 423b of the rear wall 423 of the left connecting member 420 face each other in the front-rear direction. Then, the bolt 461 that has passed through the through hole 423b passes through the through hole 314b, and is fastened to the threads of the nut 322b while sandwiching the C-shaped steel 310 and the left connecting member 420 between the bolt 461 and the nut 322b of the support member 320. It is preferable that at least one of the bolt 461 and the nuts 322a and 322b is provided with a prevention structure for preventing the bolt 461 from rotating when the bolt 461 is fastened to the nuts. Alternatively, a washer for preventing the bolt 461 from rotating may be used in combination. This prevents an excessive load from being applied to the filler 340 when the bolt 461 is fastened.

[0035] The same is true for the through-hole 422a on the left side of the through-hole 422b in the front wall 422 of the left connecting member 420. A bolt 461 passing through the through-hole 422a and a through-hole in the front wall 313 of the C-shaped steel 310 facing the through-hole 422a in the front-rear direction is fastened to the threads of the nut 322a while sandwiching the C-shaped steel 310 and the left connecting member 420 between the nut 322a. The same is true for the through-hole on the left side of the through-hole 423b in the rear wall 423 of the left connecting member 420. The left connecting member 420 and the frame member 300 are thereby fixed together.

[0036] 3 and 4, the right solar panel 520 is arranged so that the vicinity of its right front end portion is aligned with the vicinity of the left end portion of the upper surface of the ceiling wall 421 of the left connecting member 420. In this portion, the left portion of the Z-shaped metal fitting 462 sandwiches the right solar panel 520 between it and the ceiling wall 421, and the right portion of the Z-shaped metal fitting 462 and the upper surface of the ceiling wall 421 are fixed with a bolt 463 and a nut 464. This fixes the right solar panel 520 and the frame body 100.

[0037] 4, the right connecting member 430 has a configuration symmetrical to the left connecting member 420 with respect to a plane C1 perpendicular to the left-right direction, and is disposed symmetrical to the left connecting member 420. The right connecting member 430 is fixed to the frame member 300 adjacent to the right of the frame member 300 to which the left connecting member 420 is attached, in the same manner as the left connecting member 420. In addition, the left solar panel 510 is fixed to the right connecting member 430 in the same manner as the fixing structure of the left connecting member 420 and the right solar panel 520.

[0038] The intermediate connecting member 440 is a member that fixes the left connecting member 420 and the right connecting member 430 to each other, thereby fixing the frame member 300 fixed to the left connecting member 420 and the frame member 300 fixed to the right connecting member 430 to each other. As shown in FIG. 4, the intermediate connecting member 440 extends in the left-right direction and has a roughly rectangular shape in a cross section perpendicular to the left-right direction. The intermediate connecting member 440 has a U-shape that opens downward. The intermediate connecting member 440 has a ceiling wall 441, a front wall 442, and a rear wall (not shown). The ceiling wall 441 is formed with a through hole 441a used for fixing to the front-rear connecting members 450.

[0039] The front wall 442 has through holes 442a and 442b arranged symmetrically with respect to the plane C1. Similarly, the rear wall has two through holes facing the through holes 442a and 442b in the front-rear direction. The left side of the inner surfaces of the front wall 442 and the rear wall contacts the outer surfaces of the front wall 422 and the rear wall 423 of the right end of the left connecting member 420, respectively. The right side of the inner surfaces of the front wall 442 and the rear wall contacts the outer surfaces of the front wall 432 and the rear wall (not shown) of the left end of the right connecting member 430, respectively. A bolt 465 passing through the through hole 442a of the front wall 442 of the intermediate connecting member 440 and the through hole 422c of the front wall 422 of the left connecting member 420 is tightened against a nut (not shown) arranged inside the left connecting member 420 while sandwiching the intermediate connecting member 440 and the left connecting member 420 between the bolt 465 and the nut. Similarly, the bolt 465 passing through the through hole of the rear wall of the intermediate connecting member 440 and the through hole of the rear wall 423 of the left connecting member 420 is clamped between the intermediate connecting member 440 and the nut arranged on the inside of the left connecting member 420 and is tightened to the nut. This fixes the intermediate connecting member 440 and the left connecting member 420. In a similar manner, the intermediate connecting member 440 and the right connecting member 430 are fixed. This fixes the right end of one frame member 300 and the left end of the other frame member 300. In this way, the multiple frame members 300 are connected to each other by the frame body connection structure 400 and extend linearly so as to straddle the multiple solar panel sets 500 lined up in the left-right direction.

[0040] The front-rear connecting member 450 is a member that fixes the frame members 300 arranged in the front-rear direction to each other. As shown in FIG. 2, the front-rear connecting member 450 extends from the front-most frame member 300 to the rear-most frame member 300. As shown in FIG. 4, the front-rear connecting member 450 extends in the front-rear direction and has a rectangular shape in a cross section perpendicular to the front-rear direction. The front-rear connecting member 450 opens to the right. The front-rear connecting member 450 has a ceiling wall 451, a bottom wall 452, and a left wall 453. The bottom wall 452 has a plurality of through holes 452a arranged in the front-rear direction. A bolt 466 that passes through the through hole 452a of the bottom wall 452 of the front-rear connecting member 450 and the through hole 441a of the ceiling wall 441 of the intermediate connecting member 440 is tightened against the nut 467 while sandwiching the intermediate connecting member 440 and the front-rear connecting member 450 between the nut 467. This fixes the front-rear connecting members 450 and the intermediate connecting members 440. Similarly, by fixing a plurality of intermediate connecting members 440 to the front-rear connecting members 450, the frame members 300 are arranged in parallel in the front-rear direction.

[0041] As shown in FIG. 1 and FIG. 5, the panel connection structure 200 is a structure that fixes the right end of the left solar panel 510 and the left end of the right solar panel 520. The panel connection structure 200 has a base 210, a panel support member 220, and a panel clamping member 240. The base 210 is a U-shaped member that opens downward. The base 210 is fixed to the frame member 300 in a state in which it is arranged to straddle the frame member 300 in the front-rear direction. The base 210 and the frame member 300 may be fixed by any method, including welding, using bolts and nuts, etc. The upper surface of the left half of the base 210 is inclined so as to be disposed downward as it goes leftward. The right end of the left solar panel 510 is placed on this part. The upper surface of the right half of the base 210 is inclined so as to be disposed downward as it goes rightward. The left end of the right solar panel 520 is placed on this part.

[0042] A panel support member 220 is fixed to the base 210 by two sets of bolts 231 and nuts (not shown). The panel support member 220 is a U-shaped member that opens downward. The panel support member 220 is fixed to the base 210 in a state in which it is disposed so as to straddle the base 210 in the front-rear direction.

[0043] The panel clamping member 240 is a flat plate member disposed above the panel support member 220. The panel clamping member 240 is fixed to the panel support member 220 by one bolt 231 and two nuts 232. As a result, the panel clamping member 240 is fixed to the base 210 while sandwiching the left solar panel 510 and the right solar panel 520 between the panel clamping member 240 and the base 210.

[0044] A manufacturing method and an installation method of the gantry 1 will be described below. First, a manufacturing method of the frame member 300 used in the gantry 1 will be described with reference to Fig. 6. In S1, through holes 313a and 313b are formed in the right end of the front wall 313 of the C-shaped steel 310. Similarly, two through holes including through hole 314b are formed in the right end of the rear wall 314. Similarly, two through holes are formed in each of the left ends of the front wall 313 and the rear wall 314.

[0045] Next, in S2, the support material 320 is placed between the through hole 313b of the front wall 313 and the through hole 314b of the rear wall 314 (the placing step in the present invention). At that time, the support material 320 is placed in the C-shaped steel 310 so that the recess of the nut 322a of the support material 320 faces the through hole 313b in the front-rear direction and the recess of the nut 322b faces the through hole 314b of the rear wall 314 in the front-rear direction.

[0046] Also, a temporary bolt (a screw member as referred to in the present invention, not shown) is inserted into the recess of the nut 322a through the through hole 313b from the outside of the C-shaped steel 310 (insertion process as referred to in the present invention). The temporary bolt is tightened against the thread of the nut 322a while the C-shaped steel 310 is sandwiched between the temporary bolt and the nut 322a. Similarly, a temporary bolt is inserted into the recess of the nut 322b through the through hole 314b from the outside of the C-shaped steel 310 (insertion process as referred to in the present invention). The temporary bolt is tightened against the thread of the nut 322b while the C-shaped steel 310 is sandwiched between the temporary bolt and the nut 322b.

[0047] Similarly, a support member 320 is placed between the through hole 313a of the front wall 313 of the C-shaped steel 310 and the through hole of the rear wall 314, and a temporary bolt is inserted into each through hole. The C-shaped steel 310 is sandwiched between the temporary bolt and the nuts 322a and 322b, and the temporary bolt is tightened against the threads of the nuts 322a and 322b. Similarly, in two through holes arranged side by side at the left end of the front wall 313 and the rear wall 314 of the C-shaped steel 310, a support member 320 is placed between the through holes of the front wall 313 and the rear wall 314, and a temporary bolt is inserted. Then, the C-shaped steel 310 is sandwiched between the nut 322a at the front wall 313 and between the nut 322b at the rear wall 314, and the temporary bolt is tightened against the threads of the nuts 322a or 322b.

[0048] Next, the reinforcing bar 330 is placed on the support 320. Inside the C-shaped steel 310, the bars 331 and 332 are placed parallel to each other.

[0049] Next, in S3, the filler 340 before solidification is filled inside the C-shaped steel 310 (this is referred to as the filling step in the present invention). As shown in Fig. 3, the filler 340 is filled up to near the ceiling wall 311 of the C-shaped steel 310. Note that it is sufficient that the filler 340 is filled to the extent that at least the reinforcing bar 330 is embedded inside.

[0050] Next, in S4, the C-section steel 310 is left to stand until the filler 340 solidifies (this is called the solidification step in the present invention).

[0051] Next, in S5, the temporary bolts are removed from the through-holes in each of the front wall 313 and the rear wall 314. In this manner, the frame member 300 is manufactured. The manufactured frame member 300 is transported to the site.

[0052] Next, a method of installing the rack 1 on the rooftop of a building using the frame member 300 and fixing the solar panel set 500 thereto will be described.

[0053] The frame member 300 is fixed to the left connecting member 420 and the right connecting member 430. The left end of the left connecting member 420 and the right end of the C-shaped steel 310 of the frame member 300 are fixed through each other's through holes, thereby fixing the left connecting member 420 and the frame member 300. Since the through holes 422a and the like of the left connecting member 420 are long, the left connecting member 420 is attached to the C-shaped steel 310 with the bolts 461 while adjusting the attachment position. The bolts 461 may be bolts used as temporary bolts. In the same manner, the right end of the right connecting member 430 and the left end of the C-shaped steel 310 of another frame member 300 are fixed to fix the right connecting member 430 and the frame member 300. Next, the intermediate connecting member 440 is fixed to the left connecting member 420 and the right connecting member 430. At this time, since the through hole 422c of the left connecting member 420 and the through hole of the right connecting member 430 are long, the left connecting member 420 and the right connecting member 430 are attached to the intermediate connecting member 440 while adjusting the attachment positions. By repeating this, the multiple frame members 300 are connected to each other by the frame body connection structure 400. Then, the frame body 100 composed of the multiple connected frame members 300 is installed so as to straddle two adjacent beams 600 that support a rooftop structure such as a roof. This is repeated at a predetermined interval in the front-rear direction, and the multiple frame bodies 100 are arranged in the front-rear direction. Then, the intermediate connecting members 440 of the frame bodies 100 are fixed to each other by the front-rear connecting members 450.

[0054] Next, the front end and rear end of the solar panel set 500 are fixed to the frame member 300. The right front end of the right solar panel 520 is fixed to the left connecting member 420 of the frame member 300, and the left front end of the left solar panel 510 is fixed to the right connecting member 430. Similarly, the right rear end of the right solar panel 520 is fixed to the left connecting member 420 of another frame member 300, and the left end of the left solar panel 510 is fixed to the right connecting member 430. Then, the right end of the left solar panel 510 and the left end of the right solar panel 520 are fixed to the frame member 300 by the panel connecting structure part 200. In the same manner, the solar panel set 500 is fixed to the frame member 300, and multiple solar panel sets 500 are arranged in the left-right direction. Furthermore, by repeating this in the front-rear direction, multiple solar panel sets 500 are arranged in the front-rear direction.

[0055] According to the mounting stand 1 described above, the frame 100 extends long enough to straddle multiple solar panel sets 500, so the load is more easily distributed than with conventional techniques. For this reason, for example, when a fixing frame is installed for each solar panel, the load from the solar panel and the fixing frame tends to be locally generated on the rooftop structure, which is a problem associated with the conventional solar panel installation method, is less likely to occur.

[0056] On the other hand, if the frame body 100 is long, there is a high possibility that the load of the solar panel set 500 will cause deformation, such as bending, in the frame body 100. If the frame body 100 were to deform, this would result in the contact area of ​​the frame body 100 with the rooftop being localized, and there is a risk that the load of the solar panel set 500 and the mounting frame 1 would be concentrated there. To address this, the C-shaped steel 310 of the frame body 100 is filled with a filler 340. This increases the strength of the frame body 100. Therefore, deformation of the frame body 100 is suppressed, and thus concentration of the load due to deformation of the frame body 100 is suppressed.

[0057] As a result of the above, the mounting base 1 makes it easy for the load including the solar panel set 500 to be supported by the structure of the building.

[0058] Furthermore, when concrete is used as filler 340, there is a risk that the aggregate will become uneven, resulting in variations in strength; however, by using mortar as filler 340, such variations in strength can be suppressed.

[0059] Furthermore, since the filler 340 contains a binder material that improves the strength of the filler 340, the strength of the entire frame 100 is improved and damage to the filler 340 due to deterioration over time is suppressed.

[0060] Moreover, the C-shaped steel 310 has a rectangular shape in a cross section perpendicular to the left-right direction, and an opening 311c extending in the left-right direction is formed in the ceiling wall 311. This allows moisture in the C-shaped steel 310 to escape to the outside of the C-shaped steel 310 through the opening 311c, thereby suppressing damage caused by freezing of moisture in the C-shaped steel 310 and corrosion of the frame body 100.

[0061] Furthermore, in the front-rear direction of the C-shaped steel 310, a front protruding portion 311a and a rear protruding portion 311b are formed protruding from the front wall 313 and the rear wall 314 toward the opening 311c, respectively. This prevents the entire or a part of the filler 340 inside the C-shaped steel 310 from escaping from the C-shaped steel 310.

[0062] Moreover, the frame member 300 includes reinforcing bars 330 embedded in the filler 340 and supporting materials 320 that support the reinforcing bars 330 within the filler 340, and the supporting materials 320 extend along the front-rear direction of the frame member 300. The front end of the supporting material 320 contacts the inner surface of the front wall 313, and the rear end of the supporting material 320 contacts the inner surface of the rear wall 314. This allows the reinforcing bars 330 to improve the strength of the entire frame body 100. Also, the supporting materials 320 can be made to properly support the reinforcing bars 330.

[0063] Also, through holes are formed at the left end and the right end of the C-shaped steel 310. For example, through hole 313b is formed in the front wall 313 of the C-shaped steel 310, and through hole 314b is formed in the rear wall. Also, the support material 320 has nuts 322a and 322b having recesses facing the through holes 313b and 314b in the front-rear direction of the C-shaped steel 310. Threads are formed in the recesses of the nuts 322a and 322b. With these, when filling the filler 340 in the C-shaped steel 310 during the manufacture of the rack 1, the support material 320 can be appropriately supported by a temporary bolt through the through hole 313b etc. from the outside of the C-shaped steel 310. Also, the support material 320 is installed in the C-shaped steel 310. On the other hand, if the nuts 322a etc. are arranged outside the C-shaped steel 310, a protrusion protruding laterally from the side surface of the C-shaped steel 310 will be formed. Such protrusions may collide with other materials or may be damaged when the frame member 300 is transported to the site. In contrast, since the entire support material 320 is installed inside the C-shaped steel 310, no such protrusions are formed on the side surface of the C-shaped steel 310.

[0064] The frame body 100 has a plurality of frame members 300 extending in the left-right direction, and a frame body connecting structure 400 that connects the plurality of frame members 300 to each other in the left-right direction. The frame body connecting structure 400 has a left connecting member 420 and a right connecting member 430. For example, the left connecting member 420 has through holes 422a and 422b that are long in the left-right direction. The left connecting member 420 is fixed to the frame member 300 by tightening the bolts 461 that pass through the through holes 422a and 422b, respectively, to the frame member 300. This allows the overall length of the frame body 100 to be secured by connecting the frame members 300 to each other. In addition, when the left connecting member 420 is attached to the frame member 300 by the bolts 461 through the through holes 422a, etc., the attachment position can be adjusted because the through holes 422a are long.

[0065] Also, for example, the upper surface of the ceiling wall 421 of the left connecting member 420 is along a plane that is inclined downward from left to right with respect to the horizontal plane. The right solar panel 520 is disposed so that the vicinity of its right front end portion is along the vicinity of the left end portion of the upper surface of the ceiling wall 421 of the left connecting member 420. In this portion, the left portion of the Z-shaped metal fitting 462 sandwiches the right solar panel 520 between the ceiling wall 421, and the right portion of the Z-shaped metal fitting 462 and the upper surface of the ceiling wall 421 are fixed by a bolt 463 and a nut 464. This allows the right solar panel 520 to be installed on the frame 1 while being inclined along the upper surface of the left connecting member 420.

[0066] The advantages of the manufacturing method of the frame member 300 described above are as follows. For example, instead of using the support material 320, it is possible to use a relatively long screw shaft that penetrates the frame body in the width direction and attaches nuts to the bolts from both sides to tighten them. However, this method has the risk of damaging the frame body or the filler material inside by tightening the nuts from both sides. In contrast, the above method using the support material 320 has no risk of damage due to such tightening.

[0067] According to the method of installing solar panels using the mounting frame 1, the frame 100 is arranged so as to straddle two adjacent building beams 600 that support rooftop structures such as roofs. This not only distributes the load of the solar panel set 500 and the mounting frame 1 itself, but also allows the two beams 600 to appropriately support the load.

[0068] As described above, in this embodiment, (1) filling with filler 340 (mortar), (2) installing reinforcing bars 330, and (3) adding a binder material to the filler material 340 are adopted as methods for improving the strength of the frame body 100. These methods can be appropriately combined or omitted depending on the strength required for the frame body 100. In addition, it is also possible to adjust the strength of the frame body 100 by adjusting the composition of the filler material 340, the number of rods in the reinforcing bars 330 (see modified examples described later), and the type and amount of the binder material.

[0069] In addition, the frame body 100 is formed by connecting a plurality of frame members 300. Therefore, it is easy to configure the frame body 100 with an appropriate length according to the size of the area in which the solar panel set 500 is installed and the distance between the beams. In addition, it is easy to appropriately respond to the installation environment, such as when the roof on which the rack 1 is installed has an irregular shape.

[0070] Although the embodiments of the present invention have been described above based on the drawings, the specific configuration should not be considered to be limited to these embodiments. The scope of the present invention is indicated not only by the description of the above-mentioned embodiments but also by the claims, and further includes all modifications within the meaning and scope equivalent to the claims. Below, a description will be given of modified examples of the above-mentioned embodiment. In addition, the same reference numerals as those used above will be used for parts common to the above-mentioned embodiment, and the description will be omitted as appropriate.

[0071] In the embodiment, the opening 311c is formed in the ceiling wall 311 of the C-shaped steel 310. However, the opening may be formed in the bottom wall 312. In this case, the opening faces downward, making it difficult for rainwater or the like to infiltrate.

[0072] In the embodiment, the reinforcing bar 330 includes the rods 331 and 332. However, the reinforcing bar may be formed in a mesh shape by combining the rods 331 and 332 with another rod extending in the front-rear direction.

[0073] In the above embodiment, the support 320 has a round pipe 321 and nuts 322a and 322b. However, the support 320 may be a high nut. Both ends of the high nut are open and have a recess. Both ends of the recess are formed with a screw thread.

[0074] In the above embodiment, the cross section of the C-shaped steel 310 perpendicular to the left-right direction is longer in the front-rear direction than in the up-down direction. However, as shown in FIG. 7, the cross section of the C-shaped steel 710 perpendicular to the left-right direction may be longer in the up-down direction than in the up-down direction. In the above embodiment, the reinforcing bar 330 has the rods 331 and 332, and the rods 331 and 332 are arranged on the support material 320. However, as shown in FIG. 7, the reinforcing bar 730 may have the rods 731 to 734. The rods 731 and 732 are installed on the support material 320. The rods 733 and 734 are installed at the lower end of the support material 320. At this time, the rods 733 and 734 are fixed to the support material 320 by welding, bundling, or the like. In addition, the rod of the reinforcing bar 730 may be installed only at the lower end of the support material 320, may be one, or may be three or more.

[0075] The inclination angles of the upper surfaces of the ceiling walls of the left connecting member and the right connecting member may be changed according to the installation angles of the left solar panel 510 and the right solar panel 520. For example, as shown in Fig. 8, the upper surface of the ceiling wall 821 of the left connecting member 820 may be steeper inclined with respect to the horizontal plane, as compared to Fig. 4 of the above embodiment. Also, the upper surface of the ceiling wall of the left connecting member may be gentler inclined with respect to the horizontal plane, as compared to Fig. 4 of the above embodiment. Also, the inclination angle of the upper surface of the ceiling wall of the left connecting member and the inclination angle of the upper surface of the ceiling wall of the right connecting member may be different. [Explanation of symbols]

[0076] 1 Mount 100 frame 300 Frame members 310, 710 C type steel 311 Ceiling Wall 311a Front projection 311b Rear protrusion 311c aperture 313 Front wall 313a, 313b through hole 314 Back wall 314b Through hole 320 Support material 322a, 322b Nut 330, 730 Steel bars 340 Filler 420 Left connecting member 421, 821 Ceiling wall 422 Front wall 422a, 422b through hole 423 Back wall 423b Through hole 430 Right connecting member 461 Volts 500 Solar Panel Set 510 Left solar panel 520 Right solar panel

Claims

1. The solar panel is mounted on the roof of a building and has a frame for supporting the solar panel. The frame body extends linearly so as to straddle the solar panels arranged in a horizontal direction, A solar panel stand characterized in that the frame body is filled with solidified filler material.

2. 2. The solar panel stand according to claim 1, wherein the filler is mortar.

3. 2. The solar panel stand according to claim 1, wherein the filler contains a binder material that improves the strength of the filler.

4. The frame has a rectangular shape in a cross section perpendicular to its longitudinal direction, 2. The solar panel stand according to claim 1, wherein an opening extending in the length direction is formed in either a ceiling wall or a bottom wall of the frame body.

5. The solar panel stand according to claim 4, characterized in that a protrusion is formed that protrudes from a side wall of the frame body toward the opening in a width direction of the frame body.

6. A reinforcing bar embedded in the filler material; and a support material for supporting the reinforcing bar within the filler material. The support member extends along the width direction of the frame body, 2. The solar panel stand according to claim 1, wherein both ends of the support material in the width direction of the frame body are in contact with the inner surface of one side wall and the inner surface of the other side wall of the frame body, respectively.

7. a through hole is formed in each of the one side wall and the other side wall, The support member has a recess that is open at each end and faces the through hole in the width direction of the frame, 7. The solar panel stand according to claim 6, wherein a screw thread is formed in the recess.

8. The frame body is a plurality of frame members extending in the longitudinal direction; a connecting member that connects the plurality of frame members together in the longitudinal direction, A through hole is formed in the connecting member so as to be elongated in the longitudinal direction, The solar panel stand according to claim 1, characterized in that the connecting member is fixed to the frame member by a screw member passing through a through hole of the connecting member and tightening it against the frame member.

9. At least a portion of the upper surface of the connecting member is along a plane inclined relative to a horizontal plane, 9. The solar panel stand according to claim 8, wherein the solar panel is disposed along the inclined plane and fixed to the portion of the upper surface of the connecting member.

10. A method for manufacturing a solar panel stand according to claim 7, a positioning step of positioning the support material within the frame body such that the recess of the support material faces the through hole in the width direction of the frame body; an insertion step of inserting a screw member from the outside of the frame body through the through hole into the recess of the support material after the placement step; a filling step of filling the frame with the filler before solidification after the inserting step; A method for manufacturing a solar panel stand, comprising the steps of: (a) filling the frame body with a filler material;

11. A method for installing a solar panel using the solar panel stand according to any one of claims 1 to 9, A method for installing solar panels, comprising positioning the frame so as to straddle the beams of two adjacent buildings that support a rooftop structure.

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