System for fastening photovoltaic systems without using tools

Abstract

System for the installation of photovoltaic systems on flat surfaces, comprising : a plurality of longitudinal metal section bars (1) arranged in parallel to each other and in orthogonal direction to the one of the photovoltaic modules arrays, each one being introduced in a plurality of lower support elements (7), slidingly associated to said section bars (1) and provided with blocking means of the respective axial position to said longitudinal section bars; a bearing element (9) associated to each of said lower support elements; support elements (8, 14) of the photovoltaic modules, each fastened on a respective lower support element (7) so to be able to change their own tilt angle to the vertical and configured to allow the fastening of the frame of a photovoltaic module, said bearing elements (9), said support elements (8, 14) and said lower support elements (7) being provided with snap-fit type integrated fixing means, which allow their respective fastening without using tools.

Description

[0001] SYSTEM FOR FASTENING PHOTOVOLTAIC SYSTEMS WITHOUT

[0002] US ING TOOLS

[0003] The present invention relates to an installation and ballasting system for providing photovoltaic systems on flat surfaces , mainly but not exclusively buildings roofs .

[0004] In particular, the present invention relates to an installation system for photovoltaic systems allowing to reali ze rapidly and ef ficiently the installation of a photovoltaic system, with modules with both hori zontal and vertical orientatio , without using tools .

[0005] State of the art

[0006] Generally, a photovoltaic system comprises a plurality of photovoltaic modules arrays , installed parallel to each other at a defined distance in the proj ect phase as a function of the space available and the geographic position of the system . Each module of the photovoltaic array is also installed with a certain tilt to the flat surface on which the system is installed . The tilt of the module to the flat surface is defined in the proj ect phase as well as a function of the tilt of the flat surface to the hori zontal and the geographic position of the system . Technical problem

[0007] A typical problem in the installation of photovoltaic systems is to optimi ze the ef ficiency and rapidity of installation of modules support and ballasting systems .

[0008] Generally, in fact the fastening systems known at the state of the art need many tools to be assembled and do not allow to find easily a solution for the di f ferent dimensions of the photovoltaic modules , the di f ferent panels tilt or the presence of roof portions with discontinuous surface . Aim of the invention

[0009] Therefore , aim of the present invention is to provide a fastening system for photovoltaic systems on flat surfaces which overcomes the limits of the embodiments known at the state of the art , and which in particular allows the assembly by snap coupling of the various elements , allows to adj ust easily the position of the various elements of the fastening systems according to the dimensions of the modules , allows to change easily the installation angle of the photovoltaic modules , allows to install the system also on discontinuous supporting surface . Brief description of the invention

[0010] System for the installation of photovoltaic systems on flat surfaces, comprising: a plurality of longitudinal metal section bars (1) arranged in parallel to each other and in orthogonal direction to the one of the photovoltaic modules arrays, each one being introduced in a plurality of lower support elements (7) , slidingly associated to said section bars (1) and provided with blocking means of the respective axial position to said longitudinal section bars; a bearing element (9) associated to each of said lower support elements; support elements (8, 14) of the photovoltaic modules, each fastened on a respective lower support element (7) so to be able to change their own tilt angle to the vertical and configured to allow the fastening of the frame of a photovoltaic module, said bearing elements (9) , said support elements (8, 14) and said lower support elements

[0011] (7) being provided with snap-fit type integrated fixing means, which allow their respective fastening without using tools. Description of the figures

[0012] These and other advantages will be clear from the detailed description of the invention, which will refer to the appended figures 1 to 52 .

[0013] Figure 1 shows an axonometric and side view of the assembled system; figures 2 and 3 show the coupl ing of the lower support with the longitudinal section bar, shown in section view in figure 4 ; figures 5 to 8 show various views of the lower support ; figures 9 to 13 show various views of the bearing mat , also shown in figure 22 ; figures 14 to 16 show various views of the back support for photovoltaic modules , also shown in figures 23 and 24 ; figure 17 shows two views of the blocking device ; figures 18 and 19 show views of the bearing metal section bar of the photovoltaic modules ; f igure 20 shows an exploded view of the assembly of the modules front support to the lower support and the longitudinal section bar ; figure 21 shows two views of the modules front support ; figure 25 shows an exploded view of the assembly of the modules back support to the lower support and the longitudinal section bar ; figures 26 to 28 show views of the transversal section bars assembly; figures 29 to 31 show views of the photovoltaic modules assembly; figures 32 to

[0014] 35 show an adj ustment system of the lower support position to the longitudinal section bar ; figures

[0015] 36 to 40 show the piece for the connection of more section bars to each other . Figures 41 to 45 show views of ballast bearing system to be used with the system according to the invention; figures 46 to 50 show views of the windbreak case to be used with the system according to the invention; figures 51 and 52 show an alternative embodiment of the blocking system of the lower support .

[0016] Detailed description of the invention

[0017] The system allows the installation of panels ( 2 ) with hori zontal and vertical orientation and blocking by means of clamps on the long side . It is possible to install panels of any dimension with di f ferent main tilts of 5 ° , 10 ° , 15 ° and secondary tilts with intermediate angles between the above cited angles .

[0018] The main feature of the system i s the rapidity and safety in the installation by means of snap coupling of the main elements and supports without using screws or tools for the installation .

[0019] The system is made up of a main metal longitudinal section bar ( 1 ) on which two pre-assembled plastic lower supports ( 7 ) are yet provided, which will be used for the front and back fastening of the photovoltaic module . By assembl ing to each other consecutively the plurality of longitudinal section bars (1) , it is obviously possible to fasten the modules of following arrays of the photovoltaic system.

[0020] Each plastic support (7) is provided with a central through-hole (7-a) , through which the longitudinal section bar (1) can be introduced. The longitudinal section bar (1) is coupled by introduction with the central space (7a) of the lower support (7) . Preferably the shape of the longitudinal section bar comprises lower projecting tongues (Id) , configured to be introduced in respective projections (7n) of the through-hole (7-a) . So, the coupling of the section bar (1) and the support (7) is stabilized avoiding the respective sliding of the two elements.

[0021] As yet said, a longitudinal section bar (1) is conveniently associated to a plurality of fastening elements (7) , and the respective distance between two supports (7) can be adjusted according to dimensions, orientation and tilt of the photovoltaic panel (2) .

[0022] In a first embodiment, each support (7) is also associated to a blocking element (12) to fasten the axial sliding between the support (7) and the longitudinal section bar (1) . The blocking element (12) has a substantially "c" shape and comprise a first end (121) , which, by being introduced in a hole (7f) provided therefor in the lower support (7) , enters a through-hole provided on the side surface of the longitudinal section bar (1) , and a second end (122) configured to be coupled with another hole (7 e) .

[0023] In another embodiment, the second end of the blocking element (12) can engage a space (7b, 7r) , arranged in the upper portion of the section bar (7) .

[0024] In a second, not limiting embodiment of the invention, the upper surface of the longitudinal section bar (1) is associated to a sliding knurled surface (16) . Preferably said sliding knurled surface is fastened by means of rivets (17) or other similar fastening means. The aim of the provision of said knurled surface (16) is to allow the adjustment of the axial position of the single lower support (7) . In this embodiment, the fastening element (7) is associated to a lever fastening means (18) . This lever fastening means can be fastened to the support (7) , preferably by means of a groove (18-a) shaped so to be coupled with a respective projection (7-o) provided on the support (7) , on the through-hole (7-a) .

[0025] The lever fastening means (18) comprises also: a tooth (18c) configured to engage a tooth (16a) of the knurled surface (16) when the longitudinal section bar (1) is introduced in the hole (7-a) of the support (7) and a lever (18-b) configured to lift, with the action of the installer, the tooth (18c) , and to make it come elastically back in its rest position when the installer has finished.

[0026] In this way, the support (7) can slide to the section bar (1) only while a force is applied on the lever (18b) , while the knurled surface blocks the axial sliding of the support (7) to the section bar when the tooth (18c) , while coming back to its own rest position, engages the knurled surface (16) again .

[0027] As an alternative the support system (7) can be blocked by means of a pin (20-a) transversely introduced to the longitudinal section bar (1) and a spring closing element (20b) which snaps on the end of the pin.

[0028] The system comprises also, associated to each support (7) , a lower mat (9) in plastic material, with bearing function of the system on the surface where the system is installed. The mat is fastened under the support (7) , preferably by making a cylindrical seam (9h) slide inside a space of suitable shape and dimension (7g) provided on the lower surface of the support (7) . The mat (9) comprises also an abutting surface (9g) to block the respective sliding, along the axis of the seam (9h) , between the mat (9) and the support (7) .

[0029] The lower surface of the mat is at least partially covered by rough portions (92, 9f) - preferably but not limitingly obtained directly on the material of the mat (9) - which increase the adherence of the structure to the roof.

[0030] On the upper surface of the mat (9) it is also provided a series of parallel ribs (9i) to guarantee stability and resistance to breaking to outer stresses due to the wind.

[0031] Four holes (9a, 9b, 9c, 9d) are provided at the corners of the mat to introduce small blocks / screws apt to provide the mechanical fastening to the roof .

[0032] In particular, the cylindrical seam (9h) of the mat is introduced in the cylindrical space (7g) of the support (7) up to when the end portion of the seam

[0033] (91) is coupled with two elastic grasping means (7t) provided on the lower support (7) .

[0034] The snap hinge coupling between mat (9) and lower support (7) does not need screws / adhesives and at the same time makes the installation also suitable with possible misalignments of the roof.

[0035] The lower supports (7) are configured to be snap coupled without need of tools, also with the support elements for the photovoltaic modules (8, 14) .

[0036] Conveniently the supports for the modules (8, 14) , even having the same fastening manners both to the lower supports (7) and the photovoltaic modules (2) , have different dimensions if they are at the front or back bearing of a photovoltaic module (2) . In this way it is possible to install the photovoltaic module (2) inclined to the bearing plane of the structure.

[0037] To allow the fastening of the supports for the modules (8, 14) , two guide surfaces (7-c, 7-d) are positioned in the upper portion of the lower support ( 7 ) .

[0038] Such surfaces are arranged in substantially vertical direction, are faced to each other, at a suitable distance to introduce the coupling head of the supports for the modules (8, 14) and comprise each a circular through-hole, provided with a lower space, so that the circular portions of the two holes are coaxial to each other, have axis perpendicular to the development one of the central through-hole (7-a) .

[0039] Moreover, each of the two guide surfaces (7-c, 7d) is tapered in the upper portion, so to make easier the introduction of the lower portion of the support for the modules (8, 14) .

[0040] In order to allow the coupling with the lower support (7) , the supports for the modules (8, 14) comprise, in their lower portion, a coupling head configured to be introduced between said guide surface (7-c, 7-d) and provided with circular projections (14c, 81) configured to engage the circular holes provided on said guide surfaces.

[0041] In this way, once the coupling head of the supports for the modules (8, 14) is introduced between said guide surfaces, the only movement allowed between the lower support (7) and the supports for the modules is a rotation around the axis of the circular holes provided on the guide surfaces.

[0042] The supports for the modules (8, 14) comprise also radial projections (14a, 14b, 8d, 8c) configured to be coupled with respective recesses (7p) provided on the lower support, by sliding therein when the supports for the modules (8, 14) rotate to the lower support (7) .

[0043] As yet said, the assembly of the supports for the modules (8, 14) occurs by means of the introduction of the circular projections (14c, 81) of the two upper supports with the respective circular spaces provided on the lower support (7) .

[0044] Moreover, the respective rotation between the supports for the modules (8, 14) and the respective lower supports (7) allows to absorb possible installation errors due to misalignments of the roof and to variation of panels dimension.

[0045] The respective rotation is limited by an abutting tongue (14d, 8m) provided therefor on the supports (8, 14) which enters the lower space (7q) - preferably rectangular - of the circular through- hole of the two guide surfaces (7c, 7d) .

[0046] Preferably, but not limitingly, the lower support (7) comprises also through-holes (7i, 7h) , with perpendicular axis to the through-hole (7-a) where the section bar (1) can be introduced, useful for the installation, by means of self-drilling screws for plastic, of further elements, as for example windbreak cases. Conveniently, the lower support comprises also transversal ribs (7m, 71) to stiffen the piece structurally, thus guaranteeing stability and fatigue strength to wind and snow stresses.

[0047] At the same way, the supports for the modules (8, 14) are provided with side through-holes (8e, 8f, 14e) which make easier the introduction of screws or other elements for fastening cases or possible system stiffening elements.

[0048] Preferably, moreover, on the side surface of the support of the back module (8) two projecting tongues (8a, 8b) are provided configured to allow the housing of cables arranged in transversal direction to supports.

[0049] The supports for the modules (8, 14) are configured to allow the fastening of metal section bars (10) to which an edge of the photovoltaic module (2) can be fastened by means of clamps (15) . Also these connections, as it is explained in the following, can be realized without using tools.

[0050] On the upper portion of the supports for the modules (8, 14) a fastening head is provided which is provided with templates (14g, 8n) configured to provide a coupling to introduce a preferably metal section bar (10) . The blocking of said section bar (10) with the supports for the modules (8, 14) is realized by means of snap mechanical coupling of spring side pins (8i, 8h, 14f, 14h) projecting from the side surface of the supports for the modules (8, 14) with the through-hole (10a) of the metal section bar (10) .

[0051] In other terms, by introducing the section bar (10) on the upper portion of the supports for the modules (8, 14) the spring side pins (8i, 8h, 14f, 14h) move axially going back to the side surface of the supports for the modules (8, 14) and, once the through-hole (10a) of the section bar (10) is at their position, they go out again pushed by a spring thus fastening the section bar to the support for the modules (8, 14) .

[0052] In the upper portion the section bars (10) are provided with tongues (10b, 10c) with suitable width to allow the bearing of the frame of the photovoltaic modules (2) , both with horizontal and vertical orientation.

[0053] Each section bar (10) is also associated to a panel-stop element (13) , configured to be snap coupled with the section bar (10) by means of axial introduction (to the axis of the section bar 10) and introduction of a hook (13-a) in a hole (10-a) provided therefor on the section bar (10) .

[0054] The initial positioning of the panel (2) on the structure occurs with the bearing of the frame of the panel on the tongues (10b, 10c) and the following introduction of the frame itself in the space (13b) provided in the panel-stop element (13) .

[0055] The blocking of the single panel occurs by using universal pre-assembled clamps (15) , axially introduced in a groove (lOd) provided therefor on the upper surface of the metal section bar (10) , in central position to the tongues (10b, 10c) .

[0056] As it is shown in the appended figures, to provide a photovoltaic system with the just described support system, it is needed to arrange a plurality of main section bars (1) in orthogonal direction to the one of the photovoltaic modules arrays, bearing on mats (9) and to which supports for the modules (8, 14) are fastened, at a suitable distance.

[0057] To fasten the side distance between the various main section bars (1) , but also to brace the whole system and to distribute the stresses of the wind uniformly on the panels (2) , the fastening system according to the invention comprises also a plurality of stiffening transversal metal section bars (3) , arranged orthogonally to the main section bars and fastened to the same.

[0058] The fastening of the stiffening section bars (3) to the longitudinal section bar (1) is realized by using preassembled hooks (20) coupling with the base projecting tongue (3a) and fixed in the upper groove (1c) of the section bar (1) by means of connection with hammer head screw.

[0059] Said stiffening section bars are provided with a bearing tongue (3-1) , on which the first side of one or more additional ballasts (11) can be supported, whose second side can be supported on an additional stiffening section bar (3) or on an angular section bar (5) , which are fastened to the main section bars (1) as well.

[0060] In the axial direction the connection between more longitudinal section bars (1) or more transversal section bars (3) can be carried out by using a metal element (19) with suitable section to be introduced inside the main (1) or transversal (3) metal section bars. At the end of the metal element two plastic elements (4) are pre-assembled, each one with two flexible tongues (4c, 4d) at whose end a round projection (4a 4d) is provided . Preferably, the inner section of the main (1) and transversal (3) section bars is the same, so that it is possible to use indifferently the metal elements (19) . Preferably, such section is square or rectangular.

[0061] The plastic projections of the spring (4a, 4b) , provided on the side surfaces of the metal element (19) are configured to be snap coupled with respective through-holes (la, lb, 3c, 3d) provided on the side surface of the metal section bars (1, 3) .

[0062] Preferably, but not limitingly, the device comprises also a plurality of ballast support means (21) , each fastened to one of the longitudinal section bars (1) of the system.

[0063] The ballast support means (21) are configured to be positioned anywhere in the longitudinal section bar (1) •

[0064] To such aim, the longitudinal section bar (1) comprises an upper space (1c) provided with projecting tongues.

[0065] The ballast support means (21) comprises a central seam (21i) provided with two tongues (21e, 21f) configured to be introduced in the upper central space (1c) of the longitudinal section bar (1) , and, by means of a following rotation, the tongues (21e, 21f) are brought in abutment with the walls of the upper recess (1c) of the section bar.

[0066] The ballast support means (21) comprises also a knurled bearing surface (211) provided with two side containment walls (21n, 21m) opposite to each other and provided with projecting elastic tongues (21a, 21b, 21c, 21d) . So, the ballast block (11) can be supported on the knurled surface (211) of the support (21) : the presence of the four projecting tongues (21g) increases friction and stability of the ballast (21) . The two side surfaces (Ila, 11b) of the additional ballast block come in contact with the four projecting tongues (21a, 21b, 21c, 21d) provided on the two respective side containment walls (21n, 21m) . It is possible to adjust the position of the support (21) by releasing the two tongues (21e, 21f) and moving the position of the ballast block anywhere in the longitudinal section bar (1) . The advantage of using ballast support means (21) of the just described type is to distribute the weight uniformly on the whole roof avoiding to overloading the roof.

[0067] To reduce the effect of turnover and movement due to the wind, the system according to the invention comprises preferably a metal modular windbreak case (22) , fastened to the back portion of the back support for the photovoltaic modules (8) . The section bar of the case (22) is made up of a lower end (22a) and an upper end (22b) . According to the dimension of the back support (8) , the device comprises a plurality of cases (22) , up to cover the whole back surface of the high support (8) . When seen in section the section bar of the case (22) is modular, meaning that it is shaped so that the projection (22f) provided on the lower end (22a) is fixed in a recess (22b) provided at the upper end of another identical case element (22) . When the two cases (22) are coupled with each other, a tooth (22f) provided on the lower end with a respective recess (22g) provided in said recess (22b) provided at the upper end, while the upper toothed end (22d) is coupled with the recess (22e) of the lower end. In this way, a plurality of cases (22) can be assembled to each other by simply snap coupling, without using tools. The fastening of the cases (22) to the support element of modules (8) occurs with self-drilling screws (23) at the holes provided on the high support (8) after the lower case is pre-installed by coupling the hole (22h) with the projection (8h) of the support (8) . The correct positioning and respective tightening of the screws (23) is made easier by the usage of a plastic template support (24) which is preinstalled by coupling the lower recess (24b) with the circular projection (8b) provided on the high support (8) . The holes provided on the support (24a) indicate the positioning of the screws (23) .

Claims

CLAIMS1. System for the installation of photovoltaic systems on flat surfaces, comprising:- a plurality of longitudinal metal section bars (1) arranged in parallel to each other and in orthogonal direction to the one of the photovoltaic modules arrays, each one being introduced in a plurality of lower support elements (7) , slidingly associated to said section bars (1) and provided with blocking means of the respective axial position to said longitudinal section bars;- a bearing element (9) associated to each of said lower support elements; support elements (8, 14) of the photovoltaic modules, each fastened on a respective lower support element (7) so to be able to change their own tilt angle to the vertical and configured to allow the fastening of the frame of a photovoltaic module, said bearing elements (9) , said support elements (8, 14) and said lower support elements (7) being provided with snap-fit type integrated fixing means, which allow their respective fastening without using tools, each of said lower support elements (7) beingprovided with a central through-hole (7-a) in which a respective longitudinal section bar (1) can be introduced, the shape of said longitudinal section bar (1) comprising lower projecting tongues (Id) , configured to be introduced in respective projections (7n) in said through-hole (7-a) , characterized in that the upper surface of the longitudinal section bar (1) is associated to a sliding knurled surface (16) , and in that the lower support (7) is associated to a lever fastening means (18) provided with:- a tooth (18c) configured to engage a tooth (16a) of said knurled surface (16) when the longitudinal section bar (1) is introduced in the hole (7-a) of the support ( 7 ) ; a lever (18-b) configured to lift, with the action of the installer, said tooth (18c) , and to make it come back elastically in its rest position when the installer has finished.

2. System for the installation of photovoltaic systems according to claim 1, characterized in that each lower support (7) is associated to a blockingelement (12) , configured to fasten the axial sliding between the support (7) and the longitudinal section bar (1) , comprising at least an end (121) configured to be introduced in a hole (7f) on the side surface of the lower support (7) and in a corresponding through-hole provided on the side surface of the longitudinal section bar (1) .

3. System for the installation of photovoltaic systems according to one of the preceding claims, characterized in that said bearing element (9) is in plastic material, is fastened under the lower support (7) by making a cylindrical seam (9h) slide inside a space of suitable shape and dimension (7g) provided on the lower surface of said lower support (7) and in that the sliding of said cylindrical seam (9h) is limited by the coupling of the terminal portion (91) of said seam with two elastic grasping means (7t) provided therefor on the lower support .

4. System for the installation of photovoltaic systems according to one of the preceding claims, characterized in that the lower surface of said bearing element (9) is at least partially coveredby rough portions (9e, 9f) .

5. System for the installation of photovoltaic systems according to one of the preceding claims, characterized in that two guide surfaces (7-c, 7-d) are positioned in the upper portion of the lower support (7) , which are arranged in substantially vertical direction, are faced to each other, at a suitable distance to allow, by means of elastic deformation, to introduce the lower coupling head of the supports for the modules (8, 14) and comprising each a through-hole with at least a circular portion, the holes of the two surfaces being positioned so that the circular portions of the two holes are coaxial to each other and with perpendicular axis to the one of the development of the central through-hole (7-a) , said supports for the modules (8, 14) comprising, in their lower portion, a coupling head configured to be introduced between said guide surfaces (7-c, 7-d) and provided with circular projections (14c, 81) configured to engage the circular portion of the holes provided on said guide surfaces, so that once the coupling head of the supports for the modules (8, 14) is introduced between said guide surfaces,the only movement allowed between the lower support(7) and the supports for the modules is a rotation around the axis of said circular portion.

6. System for the installation of photovoltaic systems according to one of the preceding claims, characterized in that two projecting tongues (8a, 8b) are provided on the side surface of the support of back module (8) , configured to allow the housing of cables arranged in transversal direction to the supports .

7. System for the installation of photovoltaic systems according to one of the preceding claims, characterized in that said supports for the modules (8, 14) are configured to allow the fastening of metal section bars (10) to which, by means of clamps (15) , an edge of a photovoltaic module (2) can be fastened, in that said section bars (10) are provided with tongues (10b, 10c) with suitable width to allow the bearing of the frame of the photovoltaic modules (2) .

8. System for the installation of photovoltaic systems according to one of the preceding claims,further comprising a plurality of stiffening transversal metal section bars (3) , arranged orthogonally to the main section bars (1) and fastened thereto, said stiffening section bars (3) being provided with a bearing tongue (3-1) , on which a ballast (11) can be supported.

9. System for the installation of photovoltaic systems according to one of the preceding claims, characterized in that the connection in axial direction of more longitudinal section bars (1) or more transversal section bars (3) occurs by introduction, inside the two section bars to be connected, of a metal element (19) with suitable section, at whose ends plastic elements (4) are introduced, each one with two flexible tongues (4c, 4d) provided with round projection (4a, 4b) , configured to be snap coupled with respective through-holes (la, lb, 3c, 3d) provided on the side surface of the metal section bars (1, 3) .

10. System for the installation of phot ovoltaic systems according to one of the preceding claims, further comprising a plurality of ballast support means (21) , each fastened to one of said longitudinal section bars (1) , said ballastsupport means (21) being configured to be positioned anywhere in the longitudinal section bar (1) , said longitudinal section bar (1) comprising an upper space (1c) provided with projecting tongues, said ballast support means comprising a central seam (21i) provided with two tongues (21e, 21f) configured to be introduced in said upper central space (1c) of the longitudinal section bar (1) and, by means of a following rotation, the tongues (21e, 21f) to be brought in abutment against the walls of the upper recess (1c) of the section bar.

11. System for the installation of photovoltaic systems according to claim 10, further comprising a knurled bearing surface (211) provided with two side containment walls (21n, 21m) opposite to each other and provided with elastic projecting tongues (21a, 21b, 21c, 21d) .

12. System for the installation of photovoltaic systems according to one of the preceding claims, further comprising at least a metal modular windbreak case (22) , fastened to the back portion of a respective back support for the photovoltaicmodules (8) , the section bar of said case (22) comprising a lower end (22a) and an upper end (22b) configured to be fixed to each other so to assemble a plurality of cases (22) .

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