Solar panel module installation device

Abstract

This invention provides an installation device for installing solar cell modules on a roof. [Solution] The system consists of a plurality of support devices (7) arranged on the roof at predetermined intervals in the X direction, with respect to the X direction toward the ridge and eaves of the roof and the Y direction intersecting the X direction, and a long connecting member (8) that connects adjacent support devices (7)(7). The support devices (7) fix short rack members (10) on a fixed base (9) fixed to the roof, and the short rack members (10)(10) of the support devices arranged in the X direction support a pair of horizontal frame members (3b)(3b) of the frame (3) of the solar cell module. The connecting member (8) constitutes a reinforcing means (21) that connects and integrates the short rack members (10)(10) of adjacent support devices in the X direction, and also constitutes a panel receiving means (24) that extends in the X direction facing the underside of the panels (2) of the solar cell module (1) supported by the short rack members (10)(10).

Description

Technical Field

[0001] The present invention relates to an installation device for installing a solar cell module on a roof.

Background Art

[0002] Generally, a solar cell module includes a substantially rectangular frame around a solar cell panel (hereinafter simply referred to as "panel"). And, with respect to the X direction from the ridge side to the eaves side of the roof and the Y direction intersecting the X direction, the frame is composed of a pair of vertical frames extending in the X direction and a pair of horizontal frames extending in the Y direction.

[0003] Therefore, an installation device for installing a solar cell module on a roof is configured to mount the frame of the solar cell module on a rack member fixed to the roof. At that time, there are a long-rack type (Patent Document 1) in which a long rack member extending long in the X direction is fixed to the roof, and a short-rack type (Patent Document 2) in which a plurality of short rack members are fixed to the roof at intervals in the X direction, which are known.

[0004] In the case of the long-rack type, for the frame of the solar cell module mounted on the installation device, a pair of horizontal frames are supported by one long rack member. On the other hand, in the case of the short-rack type, a pair of horizontal frames are respectively supported by two short rack members adjacent to each other in the X direction.

[0005] In the case of a pitched roof, due to the relationship of fixing the rack member by sandwiching the selected ridge among the ridges arranged at a predetermined interval, in terms of the adaptability at the construction site, the short-rack type installation device is superior to the long-rack type.

[0006] Furthermore, in terms of productivity and cost, the short-rack type that can be implemented by combining short rack members is superior to the long-rack type that requires a long rack member.

Prior Art Documents

Patent Documents

[0007] [Patent Document 1] Japanese Patent Publication No. 2012-180668 [Patent Document 2] Japanese Patent Publication No. 2023-585 [Overview of the Initiative] [Problems that the invention aims to solve]

[0008] By the way, in the case of a short rack system, short rack members are individually fixed at intervals in the X direction, and the frame of the solar cell module is mounted on top of them. Therefore, when the solar cell module is buffeted by strong winds and rain, there is a risk that the fixing of the rack members, which are individually and independently installed on the roof, may loosen.

[0009] Furthermore, in areas with heavy snowfall, when the panels of a solar cell module bend downward due to snow load, there is no means of supporting the panels between adjacent short rack members in the X direction, which may lead to panel damage. In this case, although the panels have excellent flexibility and can withstand the load to some extent by bending, there is a problem that if the bent portion is pressed against the edge of the short rack member, it will easily break due to the formation of cracks.

[0010] The present invention aims to provide a solar cell module installation device that solves the above-mentioned problems while employing a short-rack type installation device that is superior in terms of on-site adaptability, productivity, and cost. [Means for solving the problem]

[0011] Therefore, the means configured in the present invention is an installation device for installing a solar cell module, which has a substantially rectangular frame around the panel, on a roof, wherein the frame is composed of a pair of vertical frames extending in the X direction and a pair of horizontal frames extending in the Y direction, with respect to the X direction toward the ridge and eaves of the roof and the Y direction intersecting the X direction, and each of the vertical and horizontal frames has a holding portion at the upper part of the base for holding the peripheral edge of the solar cell panel, and the installation device is configured to have a plurality of supports arranged on the roof at predetermined intervals in the X direction The device consists of a long connecting member that connects adjacent support devices in the X direction, the support devices are configured to fix short rack members on a fixed base fixed to the roof, and to support a pair of horizontal frame members of the solar cell module frame by the short rack members of the support devices arranged in the X direction, and the connecting member constitutes a reinforcing means that connects and integrates the short rack members of adjacent support devices in the X direction with each other, and also constitutes a panel receiving means that extends in the X direction facing the underside of the panels of the solar cell module supported by the short rack members.

[0012] In an embodiment of the present invention, the short rack material and the connecting material are configured to be fixed to each other by slidably inserting the insertion portions at both ends of the connecting material into the insertion passages of adjacent short rack materials in the X direction, and then inserting a fastener from the outside of the short rack material while the insertion portions are inserted to a predetermined position in the insertion passage.

[0013] Preferably, the connecting member has a raised portion located at least between the insertion portions at both ends, which is raised above the upper surface of the short rack material, and the raised portion constitutes the panel receiving means.

[0014] More preferably, the short rack material is formed by an upward-facing groove-shaped member with an opening at the top, and the connecting material is formed by a downward-facing groove-shaped member with an opening at the bottom. The insertion portions at both ends of the downward-facing groove-shaped member are slidably inserted into the groove of the upward-facing groove-shaped member, which serves as an insertion passage, and the groove side walls of the upward-facing groove-shaped member and the downward-facing groove-shaped member are fixed to each other with fasteners. The connecting material forms a raised portion that protrudes upward from the upper opening of the upward-facing groove-shaped member forming the short rack material. [Effects of the Invention]

[0015] The present invention provides a configuration in which multiple support devices are fixed to the roof at intervals in the X direction, and solar cell modules are mounted on top of them. This allows for the provision of the conventional short-rack type installation device described above, and is superior in terms of on-site adaptability, productivity, and cost. Furthermore, in heavy snowfall areas, by connecting the multiple support devices with long connecting members, even though it is a short-rack type installation device, when the solar cell modules are buffeted by storms, the support devices installed at intervals on the roof are integrated by the connecting members, so loosening of the fixed state of each support device can be prevented. In addition, even when the panels of the solar cell modules bend downward due to snow load, damage to the panels can be prevented by supporting them at a close position below with the panel support means provided on the connecting member. [Brief explanation of the drawing]

[0016] [Figure 1] A perspective view showing a solar cell module installed on a roof using an installation device according to an embodiment of the present invention. [Figure 2] The diagram shows a solar cell module, with (A) being a partially broken perspective view and (B) being a cross-section Z showing the panel and frame. [Figure 3] This is a perspective view showing the components of the installation device in a disassembled state. [Figure 4]Regarding an embodiment of the installation device, (A) is a perspective view showing a fixed base and a short rack material that constitute the support device, and a connecting material in a disassembled state, (B) is a cross-sectional view of the short rack material, and (C) is a cross-sectional view showing an insertion portion of the short rack material and the connecting material. [Figure 5] Regarding a saddle roof, (A) is a perspective view showing a method of fixing a fixed base of an installation device to a roof having a lateral saddle, and (B) is a perspective view showing a method of fixing a fixed base of an installation device to a roof having a longitudinal saddle. [Figure 6] It is a perspective view showing a state in which an installation device is assembled and fixed on a roof regarding an embodiment of the installation device. [Figure 7] Regarding a state in which a solar cell module is installed by an installation device, (A) is a cross-sectional view showing a cross-section in the X direction, and (B) is a cross-sectional view showing a cross-section in the Y direction. [Figure 8] It shows a cross-section in the X direction of an installation device equipped with a solar cell module. (A) is a cross-sectional view showing a state when no load is acting on the panel of the solar cell module, and (B) is a cross-sectional view showing a state when a load is acting on the panel of the solar cell module. [Figure 9] It shows a cross-section in the Y direction of an installation device equipped with a solar cell module. (A) is a cross-sectional view showing a state when no load is acting on the panel of the solar cell module, and (B) is a cross-sectional view showing a state when a load is acting on the panel of the solar cell module. [Figure 10] It shows a comparative example without a connecting material. (A) is a cross-sectional view showing a state when no load is acting on the panel of the solar cell module, and (B) is a cross-sectional view showing a state when a load is acting on the panel of the solar cell module.

Embodiments for Carrying Out the Invention

[0017] The preferred embodiments of the present invention will be described in detail based on the following drawings.

[0018] As shown in Figure 1, the solar cell module 1 is installed on the roof using the installation device of the present invention, and is laid out in parallel in the X direction toward the ridge and eaves of the roof, and in the Y direction intersecting the X direction. In Figure 1, the eaves side of the roof is indicated by X1 and the ridge side by X2, and in the X direction, it shows a state in which two solar cell modules, solar cell module 1a on the eaves side and solar cell module 1b on the ridge side, are installed side by side, but three or more solar cell modules can be installed side by side as needed.

[0019] As shown in Figures 1 and 2(A), the solar cell module 1 is equipped with a substantially rectangular frame 3 around the panel 2. The frame 3 is composed of a pair of vertical frames 3a, 3a extending in the X direction and a pair of horizontal frames 3b, 3b extending in the Y direction, with a gap LP between the pair of horizontal frames 3b, 3b. As shown in Figure 2(B), the vertical frame 3a and the horizontal frame 3b are each provided with a holding portion 5 on the upper part of the base 4, which has a groove for holding the peripheral edge of the panel 2. Therefore, the panel 2 is held at a height HP from the bottom surface of the base 4.

[0020] The installation device 6 consists of a plurality of support devices 7 arranged on the roof at predetermined intervals in the X direction, and a long connecting member 8 that connects adjacent support devices 7, 7 in the X direction, with multiple installation devices 6 arranged side by side at intervals in the Y direction.

[0021] As shown in Figures 3 and 4, the installation device 6 in the illustrated embodiment consists of a unit comprising three support devices: a first support device 7a, a second support device 7b, and a third support device 7c, which are arranged sequentially from the eaves side to the ridge side, and two connecting members 8, 8 that connect adjacent support devices 7. In this case, the horizontal frames 3b, 3b of the solar cell module 1a on the eaves side are supported by the first support device 7a and the second support device 7b, and the horizontal frames 3b, 3b of the solar cell module 1b on the ridge side are supported by the second support device 7b and the third support device 7c.

[0022] Furthermore, when installing a third solar cell module 1 in parallel toward the ridge, a fourth support device 7 is placed at a predetermined distance from the eaves side of the third support device 7c and connected via a connecting member 8, making it possible to support the horizontal frames 3b, 3b of the third solar cell module 1 with the third support device and the fourth support device.

[0023] The support device 7 consists of a fixed base 9 that is fixed to the roof and short rack material 10 that is fixed on top of it.

[0024] The aforementioned mounting base 9 is provided with fastening means 11 that are fixed to the roof, and has a mounting surface 12 formed on its upper surface, from which mounting bolts 13 are erected.

[0025] The fastening means 11 is of a known configuration, but in the illustrated embodiment, as shown in Figure 5, it is configured to clamp the ridge 14 of the ridged roof, and is configured so that short rack material 10 can be placed and fixed while it is fixed to the roof, whether it is a horizontal ridge 14a extending in the Y direction as shown in Figure 5(A) or a vertical ridge 14b extending in the X direction as shown in Figure 5(B).

[0026] (Composition of short rack materials and connecting materials) As shown in Figures 3 to 6, the short rack material 10 is installed on a plurality of fastening means 11 (two in the illustrated example) arranged in the X direction. As shown in Figure 4, in the illustrated embodiment, the short rack material 10 is formed of an upward-facing groove-shaped member made of metal and has a bottom wall 11a, side walls 11b, 11b bent upward from both side edges of the bottom wall 11a, lips 11c, 11c bent inward from the upper ends of the side walls, and an upper opening 11d located between the two lips.

[0027] The bottom wall 11a is provided with elongated holes 11e extending in the X direction from near both ends. As a result, the short rack material 10 is mounted in a fixed state on the fixing base 9 by placing the bottom wall 11a on the mounting surface 12 of the fixing base 9, inserting the mounting bolts 13 through the elongated holes 11e, and screwing nuts 13a onto the mounting bolts 13.

[0028] The short rack material 10, formed by a groove-shaped member, has an insertion passage 15 formed by the groove, thereby allowing the insertion portions 16 formed at both ends of the connecting material 8 to be slidably inserted into the insertion passage 15.

[0029] As shown in Figure 4, the connecting member 8 is formed from a long, downward-facing groove-shaped metal member, and includes side walls 8b, 8b bent downward from both side edges of the upper wall 8a, and rail portions 8c bent inward from the lower ends of the side walls. In the illustrated embodiment, the upper wall 8a forms a raised portion 18 that rises upward between the strip-shaped portions 17, 17 bent from the upper end edges of the side walls 8b, 8b.

[0030] As shown in Figure 6, the distance L between adjacent support devices 7 in the X direction at approximately their center (Figure 6 shows the distance between the first support device 7a and the second support device 7b, but the distance between the second support device 7b and the third support device 7c is approximately the same) corresponds to the distance LP between the pair of horizontal frames 3b, 3b in the solar cell module 1 described above. The insertion portions 16 at both ends of the connecting member 8 are slidably inserted into the insertion passages 15 of the short rack material 10 in adjacent support devices 7, 7, and the two support devices are fixed to each other by inserting fasteners 19 such as screws from both side walls 11b of the short rack material 10.

[0031] In this case, the side walls 11b of the short rack material 10 are provided with numerous holes 20 at predetermined intervals in the longitudinal direction (X direction), and in the illustrated example, the fastener 19 is made of tapping screws. Therefore, the insertion portion 16 of the connecting material 8 is inserted into the insertion passage 15 of the short rack material 10, the insertion length is adjusted and confirmed by sliding the insertion portion 16, and then the fastener can be secured by screwing the screws through the holes 20.

[0032] As shown in Figure 4(C), the connecting member 8 inserted into the short rack member 10 has its high portion 18 protruding upward from the upper opening 11d of the short rack member 10.

[0033] As a result, the connecting member 8 constitutes a reinforcing means 21 that connects and integrates the spaced-apart short rack members 10, 10 with one another, and the multiple support devices 7 are connected and integrated by the connecting member 8, thereby providing an installation device 6 with high overall rigidity.

[0034] As shown in Figure 7, the solar cell module 1a on the eaves side is placed and fixed on the short rack members 10, 10 of the first support device 7a and the second support device 7b, which are adjacent in the X direction, by the pair of horizontal frames 3b, 3b of the frame 3. Similarly, the solar cell module 1b on the ridge side is placed and fixed on the short rack members 10, 10 of the second support device 7b and the third support device 7c, which are adjacent in the X direction, by the pair of horizontal frames 3b, 3b of the frame 3.

[0035] The horizontal frame 3b located on the eaves side of the solar cell module 1a on the eaves side and the horizontal frame 3b located on the ridge side of the solar cell module 1b on the ridge side are fixed to the short rack material 10 of the first support device 7a and the third support device 7c, respectively, with the horizontal frame 3b being pressed down from above by the end retaining bracket 22.

[0036] The horizontal frame 3b located on the ridge side of the solar cell module 1a on the eaves side and the horizontal frame 3b located on the eaves side of the solar cell module 1b on the ridge side are adjacent to each other with a narrow gap between them, and by inserting the intermediate retaining bracket 23, which has a roughly T-shaped cross section, into the gap, the horizontal frames 3b, 3b are fixed to the short rack material 10 of the second support device 7b while being pressed down from above.

[0037] In this state, each connecting member 8 constitutes a panel receiving means 24 that extends in the X direction facing the underside of the panel 2 of each solar cell module 1. In the illustrated embodiment, the panel receiving means 24 is formed by the higher portion 18 of the connecting member 8 and faces the underside of the panel 2 in close proximity, as shown by the separation distance h in Figure 7.

[0038] (action) Figures 8(A) and 9(A) show the normal state in which no load is acting on the solar cell module 1, while Figures 8(B) and 9(B) show the state when a load such as snow is acting on the solar cell module 1.

[0039] As shown in Figures 8(B) and 9(B), when subjected to loads such as snow, the panel 2 of the solar cell module 1 bends downward, but is supported by contact with the panel support means 24. Therefore, it does not bend downward beyond the aforementioned separation distance h (see Figure 7), nor does it come into contact with the edge E of the short rack material 10. As a result, the bent panel 2 can withstand loads such as snow while being supported by the panel support means 24, thus preventing damage to the panel 2.

[0040] To facilitate understanding of the above operation, Figure 10 shows a comparative example of an installation device 6 without a panel receiving means 24, with the solar cell module 1 mounted, by removing the connecting member 8 from the above embodiment.

[0041] In the comparative example, when a load such as snow is applied from the state shown in Figure 10(A) where no load is applied, the panel 2 will bend significantly downward, as shown in Figure 10(B). In this case, since the panel 2 has excellent flexibility, it can withstand the load to some extent by bending, but the bent portion is pressed against the edge E of the short rack material 10, causing cracks to form at the point of contact with the edge E, and it will easily break. In contrast, according to the embodiment of the present invention, since the panel support means 24 is provided, damage to the panel 2 is suitably prevented.

[0042] Moreover, in the comparative example, even in the unloaded state shown in Figure 10(A), the first support device 7a and the second support device 7b are individually fixed with a gap in the X direction, and the horizontal frames 3b, 3b of the solar cell module 1 are mounted on top of them. Therefore, when the solar cell module 1 is subjected to strong winds and rain, and is buffeted or twisted, the fixing state of one or both of the first support device 7a and the second support device 7b, which are individually and independently arranged on the roof, may easily loosen. In contrast, according to the embodiment of the present invention, the first support device 7a and the second support device 7b are connected and integrated by a connecting member 8 that constitutes the reinforcing means 21, and the solar cell module 1 is supported in a rigid state, so the occurrence of loosening from the fixed state is effectively prevented. [Explanation of Symbols]

[0043] 1. Solar cell module 1a Solar panel module on the eaves side Solar modules on the side of building 1b 2 panels 3 Frame 3a vertical frame 3b horizontal frame 4 base 5 Holding part 6 Installation equipment 7 Support device 7a First support device 7b Second support device 7c Third support device 8 Connecting material 8a Upper wall 8b side wall 8c Rail section 9 Fixed base 10 Short rack materials 11a Bottom wall 11b Side wall 11c Lip 11d Upper opening 11e long hole 11 Fixing means 12 Mounting surface 13 Mounting bolts 13a Nut 14 Hase 14a Yokobe 14b Vertical line 15 Insertion passage 16 Insertion part 17. Band-shaped portion 18 High part 19 Fasteners 20 holes 21 Reinforcement means 22 End retaining clips 23 Intermediate retaining clip 24 Panel receiving means

Claims

1. This is an installation device for mounting solar cell modules, which have a roughly rectangular frame around the panel, onto a roof. With respect to the X-direction toward the ridge and eaves of the roof, and the Y-direction intersecting the X-direction, the frame is composed of a pair of vertical frames extending in the X-direction and a pair of horizontal frames extending in the Y-direction, and each of the vertical and horizontal frames is provided with a holding portion at the upper part of its base for holding the peripheral edge of the solar panel, The installation device consists of a plurality of support devices (7) arranged on the roof at predetermined intervals in the X direction, and a long connecting member (8) that connects adjacent support devices (7)(7) in the X direction. The support device (7) is configured to fix short rack members (10) on a fixed base (9) fixed to the roof, and to support a pair of horizontal frame members (3b)(3b) of the solar cell module frame (3) with the short rack members (10)(10) of the support device arranged in the X direction. The solar cell module installation device is characterized in that the connecting member (8) constitutes a reinforcing means (21) that connects and integrates adjacent short rack members (10)(10) of support devices in the X direction, and also constitutes a panel receiving means (24) that extends in the X direction facing the lower side of the panel (2) of the solar cell module (1) supported by the short rack members (10)(10).

2. The solar cell module installation device according to claim 1, characterized in that the short rack members and connecting members are configured to be fixed to each other by slidably inserting the insertion portions (16) (16) at both ends of the connecting member (8) into the insertion passages (15) of adjacent short rack members (10) (10) in the X direction, and then inserting a fastener (19) from the outside of the short rack member (10) while the insertion portions (16) are inserted to a predetermined position in the insertion passages (15).

3. The solar cell module installation device according to claim 2, characterized in that the connecting member (8) has a raised portion (18) located at least between the insertion portions (16) (16) at both ends and which protrudes above the upper surface of the short rack member (10), and the raised portion constitutes the panel receiving means (24).

4. The short rack material (10) is formed by an upward-facing groove-shaped member with an opening at the top, and the connecting material (8) is formed by a downward-facing groove-shaped member with an opening at the bottom. The groove portion of the upward groove-shaped member is used as an insertion passage (15) to which the insertion portions (16)(16) at both ends of the downward groove-shaped member are slidably inserted, and the groove side walls (11b)(8b) of the upward groove-shaped member and the downward groove-shaped member are fixed to each other with fasteners (19). The solar cell module installation device according to claim 3, characterized in that the connecting member (8) has a raised portion (18) that rises upward from the upper opening (11d) of the upward groove-shaped member that forms the short rack member (10).

Images