Photovoltaic module, photovoltaic system and method for mounting a photovoltaic module

Abstract

The invention relates to a photovoltaic module (101) having a front side (161), a rear side (163), a photovoltaic element (105), a protective structure (201, 205) and an electrical terminal (253), wherein the protective structure areally covers the photovoltaic element for protection and wherein the photovoltaic element converts incident light into electrical power and provides the electrical power at the electrical terminal. The photovoltaic module is supported for deformation prevention by means of at least one rear-side-fastened support profile (121, 123, 125) along a support profile longitudinal axis (181) and along a support profile cross-section (122, 124, 126) extending along the support profile longitudinal axis, by virtue of the stiffness of the support profile. Proceeding from a central region (131), the support profile cross-section forms a first profile leg (135) having a first end region (143) and a second profile leg (139) having a second end region (147), the first end region and the second end region being fastened to the rear side of the photovoltaic module, and in the central region a mounting surface (131) for mounting the photovoltaic module on a base surface (171) is formed, the mounting surface being spaced apart from the rear side by the length of the profile legs. The invention further relates to a photovoltaic system and to a method for mounting a photovoltaic module.

Description

[0001] Photovoltaic module, photovoltaic system and methods for

[0002] Mounting a photovoltaic module

[0003]

[0001] The invention relates to a photovoltaic module according to the preamble of claim 1. Furthermore, the invention relates to a photovoltaic system according to claim 11 and a method for mounting a photovoltaic module according to claim 12.

[0004]

[0002] Known photovoltaic modules are, for example, equipped with a protective glass front and a plastic cover or glass pane on the back. An aluminum frame typically runs around the modules. This stabilizes the photovoltaic module against warping or other deformation and protects the edge from damage. Furthermore, support profiles serve for additional stiffening and often act as mounting profiles to, for example, a roof or wall. However, on many flat roofs, the frames should not be attached to the roof's supporting structure, for example, using multiple brackets, because this would penetrate the roof's waterproof layer in many places, creating a risk of leaks. Alternatively, the framed modules can be weighted down with profiles and weights, so-called ballasted, to prevent them from being lifted off during storms.The corresponding additional loads can, however, often overload roofs, and especially large commercial roofs.

[0003] Therefore, lightweight PV modules have been known for some years which are glued to the roof on their back side using adhesive beads. This allows large additional roof areas to be used for photovoltaics. Most of these modules have a polymer front and back. Modules with a glass front and a polymer back are also known. In addition, modules with a polymer front and back are known which have a mounting on the back. If these modules are to be glued evenly to the roof, adhesive must be applied to the side of the profiles facing the roof. This adhesive must be applied thickly to compensate for differences in thermal expansion, for example, and to remain permanently flexible.This results in a significant amount of adhesive being used, and on-site gluing is associated with considerable time and material costs, also because large areas of the profile often need to be glued. Furthermore, known profiles create frame-like structures around the module, which impede convection behind the module. This causes the module to run hotter during operation than with unimpeded convection. A frame that impedes convection should therefore be avoided, as photovoltaic cells lose efficiency with increasing temperature.

[0005]

[0004] DE 10 2008 050 529 discloses a photovoltaic system with a substructure. Profile bodies with retaining lugs are used to suspend a photovoltaic module by means of an intermediate profile and retaining pockets arranged therein, thus enabling it to be detachably fastened.

[0006]

[0005] US 2015 / 0059833 A1 describes a bolted substructure for solar modules. Profile parts are connected to a respective solar module and then screwed onto rectangular profiles.

[0007]

[0006] In CN 217924294 U, a solar arrangement is disclosed, wherein a respective solar module is attached to a facade by means of a profile.

[0008]

[0007] The object of the invention is to improve the state of the art.

[0009]

[0008] The problem is solved by a photovoltaic module according to claim 1. Advantageous embodiments of the invention are described in claims 2 to 10.

[0010]

[0009] A key concept of the invention is that the support profile cross-section is oriented with at least two end regions towards the rear of the photovoltaic module, with a single central region facing away from the photovoltaic module to form a mounting surface. Consequently, the photovoltaic module can be installed and fastened to only the single mounting surface per support profile. This is done, for example, by screwing or gluing. Gluing has the advantage that roof penetrations and thus potential leaks are avoided. Ballasting the modules is also unnecessary, which means that the modules can also be installed on roofs with load-bearing capacity restrictions and reduces transport costs.It is sufficient to apply a single bead of adhesive to the individual mounting surface between the profile legs, or, for example, to insert a single screw or a single suspension connection to attach the photovoltaic module. Likewise, a key aspect of the invention is the use of a rollable, flat adhesive, particularly double-sided adhesive tape, for bonding, especially for connecting the photovoltaic module to the support profile on a substrate. The double-sided adhesive tape can, in particular, consist of a weather-resistant acrylate adhesive and / or be provided with fabric reinforcement. In particular, the mounting of the photovoltaic module is free of any additional profile components in contact with the substrate; it is bonded directly to the substrate along with the support profile.It should be mentioned that double-sided adhesive tape can be pre-applied directly to the mounting surface of the support profile, for example, to prepare for assembly.

[0011]

[0010] The substrate is, in particular, a roof or a flat roof, with the support profile serving especially to create a ventilation space and to reinforce the photovoltaic module against bending and / or breakage. Furthermore, the support profile can increase the distance to water accumulation on the roof. For example, UV-sensitive connection and bypass diodes made of plastic, as well as connection cables, can be arranged on the back of the modules, unlike with conventional adhesive modules, thus protecting them from UV light and weathering. In contrast to photovoltaic modules mounted without support profiles, for example, module inverters or power optimizers can also be attached to the back of the photovoltaic modules.

[0012]

[0011] Furthermore, the support profile can have a cross-section that increases along its length, so that the respective photovoltaic module can be attached and / or mounted at an angle formed by the increasing cross-section of the support profile, for example, on a roof. This allows, for example, a flat roof with a slope of only a few degrees to be equipped with a corresponding photovoltaic module, whereby the angle of the support profile along its length can be adjusted, for example, to adapt the angular position of the photovoltaic module to an expected position of the sun.

[0013]

[0012] Contact surfaces can be formed at the respective end regions, and these contact surfaces can be oriented substantially parallel to the rear of the photovoltaic module. This allows, for example, a planar connection to the rear of the photovoltaic module to be created, which is formed, for example, during the manufacturing of the photovoltaic module. This connection can be made, for example, by welding, screwing, or gluing. In particular, the support profile is a trapezoidal profile or a Q-profile.

[0013] Likewise, the mounting surface can also be oriented substantially parallel to the rear of the photovoltaic module, so that a flat and planar mounting can be carried out, for example, on a substrate such as a wall or a roof.

[0014]

[0014] In particular, for example, junction boxes and associated cables of the photovoltaic module can be mounted on the back of the module and between corresponding support profiles, thus protecting them from UV light and weathering such as snow or rain. For easy installation, both junction boxes should be equipped with cables that extend to the edge of the respective module. It should be noted that the length of the cable, especially a cable pre-assembled on the photovoltaic module, is dimensioned such that every edge area of ​​the photovoltaic module is accessible, thus enabling pre-assembly regardless of orientation. Therefore, it is irrelevant for subsequent installation whether the photovoltaic module is to be mounted in a horizontal or vertical position; an electrical connection is always possible with the pre-assembled cable of this dimension.To optimize the fire protection of the junction boxes and cables, these can also be arranged within a non-combustible support profile and / or made of non-combustible materials.

[0015]

[0015] According to one embodiment of the invention, it is advantageous that the material used for the support profile is non-combustible. Metals are particularly non-combustible. However, metals are electrically conductive, which may necessitate grounding. In particular, glass fiber reinforced plastic (GFRP) can therefore be used as the material for the support profiles.

[0016]

[0016] The support profile can be designed, in particular, as a sheet metal edge section, wherein the respective profile legs and the central area, as well as the respective contact surfaces or the mounting surface, can be formed by bending a sheet metal part. A "sheet metal part" can be a metallic sheet or, for example, a plastic sheet or a plastic surface, i.e., a planar structure made of a thermoplastic or thermoset, particularly fiber-reinforced, plastic. For example, a corresponding bend can then be formed by deep drawing or hot forming of a thermoplastic or by primary forming of a fiber-reinforced plastic. Thus, the support profile can also be designed as a molded plastic part.

[0017]

[0017] Likewise, the support profile can be designed as an extruded profile, either made of a metal or a plastic. For example, an extruded profile can be produced from aluminum or a thermoplastic to form the support profile.

[0018]

[0018] For example, if one or more openings or one or more breaks are arranged in the support profile along the longitudinal axis of the support profile, particularly in the respective profile leg, this can reduce the weight of the support profile. It also allows for the routing and, in particular, the fastening of cables, for example with the aid of cable ties.In this context, a "penetration" refers, for example, to a hole or opening in the profile leg for routing cables or cable ties, or as a ventilation opening. A "break" refers to a corresponding separation along the longitudinal axis of the support profile through a portion, a large portion, or the entire cross-section. This allows the support profile to be, for example, offset along its longitudinal axis or, through a complete break, installed in multiple sections on the back of the photovoltaic module. Partial breaks in the cross-section, in particular, can be used to adjust the stiffness of the support profile, for example, to create a defined flexibility and thus enable adaptation to slightly curved or uneven surfaces.This makes installation on uneven surfaces or substrates particularly easier. Furthermore, accessibility for installation can be improved if, for example, openings or breaks can be used for installing screws, cables, or checking adhesive bonds. Similarly, a complete break can be provided in such a way as to achieve improved ventilation or to facilitate cable installation. For this purpose, the respective support profile can, for example, be designed with breaks at regular intervals.

[0019]

[0019] It should be mentioned that by arranging the support profile on the rear side of the photovoltaic module, and at a corresponding height of the support profile behind the photovoltaic module, i.e., between the rear side and the subsequent installation surface, a space remains for, for example, junction boxes or installation materials. Furthermore, ventilation of the photovoltaic module from the rear side is ensured. The openings or interruptions can also contribute to this by, for example, keeping a ventilation space or ventilation paths clear.

[0020]

[0020] The protective structure of the photovoltaic module can, in particular, comprise a front protective cover and / or a rear protective cover, wherein the respective protective cover is, in particular, made of glass with a thin profile, for example, less than 3 mm, less than 2 mm, less than 1.5 mm, or less than 1 mm. The geometric design of the respective support profile allows even a photovoltaic module with a very thin glass structure to be stabilized in such a way that its service life is sufficiently long. A rear protective cover made of thin glass, for example, 1.5 mm or 1 mm thick, is particularly suitable for bonding the support profiles to the rear of the photovoltaic module.

[0021]

[0021] In a further aspect, the problem is solved by a photovoltaic system according to claim 11. The photovoltaic system is formed from one or more photovoltaic modules according to one of the previously described embodiments, wherein the corresponding photovoltaic modules are, for example, electrically contacted and thus jointly provide electrical energy. In particular, the photovoltaic system is formed by mounting the photovoltaic modules on a roof.

[0022]

[0022] In this process, corresponding photovoltaic modules are connected to the substrate, in particular at the respective mounting surface, by means of adhesive bonding, especially by means of a double-sided adhesive tape, whereby the application of an adhesive bead in front of the respective individual mounting surface is greatly simplified.

[0023]

[0023] In a further aspect, the problem is solved by a method for mounting a photovoltaic module according to claim 12. In this method, an adhesive is applied to the respective individual mounting surface, so that the photovoltaic module can then be easily bonded to the substrate without, for example, having to apply several beads of adhesive to each support profile. If a double-sided adhesive tape is used, the double-sided adhesive tape can be pre-applied to the respective mounting surface, thus simplifying the mounting of the respective photovoltaic module on a roof or facade.

[0024]

[0024] The invention will now be explained in more detail with reference to exemplary embodiments. Figure 1 shows a schematic representation of a solar module mounted on a house wall, as well as

[0025] Figure 2 is a schematic sectional view of the

[0026] Solar module of Figure 1 .

[0027]

[0025] A solar module 101 is mounted on a house wall 171. The solar module 101 is thus mounted with a solar surface 103 facing away from the house wall 171, so that solar cells 105 in the solar module 101 can absorb light and provide electrical energy. To protect the solar cells 105 and, in particular, the edges of the solar module 101, the solar module 101 has a frame 107, although this frame 107 can also be omitted. Alternatively, the solar module 101 can, for example, also be mounted on a flat roof or a pitched flat roof.

[0028]

[0026] On a front side 161, the solar module 101 has a protective glass 201 which covers an interior space 203. The interior space 203 serves to house the solar cells 105 and, for example, electrical connections. The protective glass 201 is approximately 2 mm thick. On a rear side 163, another protective glass 205 is arranged, which is approximately 1.5 mm thick. The protective glass 201 and 205 serve to protect the solar cells 105 against, for example, hail damage and are protectively enclosed by the frame 107.

[0029]

[0027] The solar module 101 is arranged on the house wall 171 by means of support profiles 121 , 123 and 125 , wherein the support profiles have a respective cross-section 122 , 124 and 126 and serve to stiffen the solar module 101 and at the same time to mount it.

[0030]

[0028] The support profiles are designed identically; the following explanation is based on support profile 121 as an example:

[0031]

[0029] The cross-section 122 of the support profile 121 is trapezoidal and has a mounting area 131 parallel to the house wall 171. A subsequent bend 133 forms a leg 135 adjoining the mounting area 131, and symmetrically to this, a leg 139 is formed by a bend 137, each with a bend angle of approximately 60°. The support profiles are made from bent sheet steel. Alternatively, the support profiles can also be made from plastic by deep drawing or hot forming.

[0032]

[0030] In a respective end region 143 and 147, which is subsequently formed on the legs 135 and 139 by a respective bend 141 and 145, the support profile 121 then runs parallel to the house wall 171 and thus parallel to the mounting area 131. The support profile 121 is fixed and mounted to the rear 163 of the solar module 101 by means of adhesive beads 151 and 153, these adhesive beads 151 and 153 being already applied at the factory.

[0033]

[0031] The mounting area 131 is mounted to the house wall 171 by means of an adhesive bead 155, whereby this adhesive bead 155 is applied to the mounting area 131 during the mounting of the solar module 101 to the house wall 171, so that only a single adhesive bead is required for each support profile. It should be noted that instead of the adhesive bead 155, a double-sided adhesive tape can also be pre-applied and used for mounting on the house wall 171 or, for example, a flat roof, in order to further reduce the installation effort.

[0034]

[0032] It should also be noted that the support profile 121 has openings 149 along its support profile axis 181, which serve both for routing cables and for attaching, for example, additional material. Furthermore, the openings 149 can facilitate ventilation on the rear side 163 of the solar module 101.

[0035]

[0033] In the area of ​​the rear side 163, the support profile creates a space opposite the house wall 171, in which a junction box 251 and connecting cables 253 for electrically contacting the solar cells 105 can be arranged. For example, the junction box 251 is glued to the protective glass 205 on the rear side 163 of the solar module 101.

[0036]

[0034] For mounting on a flat roof (not shown), the cross-section 122 of the support profile 121 can also be designed to increase in height along the length of the support profile 121, so that, in particular, an increasing height is achieved at a height between the mounting surface and the solar module 101, thus enabling, for example, mounting on a sloping flat roof with a correspondingly greater inclination of the solar module 101. Reference list

[0037] 101 solar module

[0038] 103 solar panels

[0039] 105 solar cells

[0040] 107 frames

[0041] 121 Support profile

[0042] 122 Cross section

[0043] 123 Support profile

[0044] 124 Cross section

[0045] 125 support profile

[0046] 126 Cross section

[0047] 131 Assembly area

[0048] 133 Edge

[0049] 135 thighs

[0050] 137 Edge

[0051] 139 thighs

[0052] 141 Edge

[0053] 143 End range

[0054] 145° bend

[0055] 147 End range

[0056] 149 Breakthrough

[0057] 151 Adhesive caterpillar

[0058] 153 Adhesive caterpillar

[0059] 155 adhesive caterpillar

[0060] 161 Front

[0061] 163 reverse

[0062] 171 House wall

[0063] 181 Support profile axis 201 Protective glass

[0064] 203 Interior

[0065] 205 Protective glass

[0066] 251 Junction box 253 Connection cable

Claims

Patent claims:

1. Photovoltaic module (101) with a front (161), a back (163), a photovoltaic element (105), a protective structure (201, 205) and an electrical connection (253), wherein the protective structure (201, 205) Photovoltaic element (105) is covered over its entire surface for protection, and the photovoltaic element converts incident light into electrical power and provides the electrical power at the electrical connection (253), wherein the photovoltaic module is supported by means of at least one support profile (121, 123, 125) fixed to the rear (163) along a support profile longitudinal axis (181) and a support profile along the longitudinal axis of the support profile (181) Support profile cross-section (122, 124, 126) through a Stiffness of the support profile (121, 123, 125) against deformation is supported, characterized in that the support profile cross-section (122, 124, 126) forms a first profile leg (135) with a first end region (143) and a second profile leg (139) with a second end region (147) starting from a central region (131), wherein the first end region (143) and the second end region (147) are fixed to the rear (163) of the photovoltaic module and a mounting surface (131) for mounting the photovoltaic module on a substrate (171) is formed on the central region (131) spaced apart from the rear (163) by a length of the profile legs (135, 139).

2. Photovoltaic module according to claim 1, characterized in that a first contact surface (143) and / or a second contact surface (147) to the rear side (163) of the first end region (143) is provided and / or a second contact surface (147) is provided at the second end region (147). photovoltaic module is or are formed, wherein the first contact surface (143) and / or the second contact surface (147) is or are oriented in particular substantially parallel to the rear side (163) of the photovoltaic module, wherein the first contact surface (143) and the second contact surface (147) are in particular arranged in a common contact plane.

3. Photovoltaic module according to claim 1 or 2, characterized in that the mounting surface (131) is oriented substantially parallel to the rear side (163) of the photovoltaic module and / or the support profile has a support profile cross-section that increases along a length of the support profile, so that the respective photovoltaic module can be attached and / or mounted at an angle formed by the increasing support profile cross-section.

4. Photovoltaic module according to one of the preceding claims, characterized in that the support profile (121, 123, 125) is designed as a sheet metal edge part, wherein the first profile leg (135), the second profile leg (139) and the central area (131) and in particular the first contact surface (143), the second contact surface (147) and / or the mounting surface (131) are formed by bending a sheet metal part.

5. Photovoltaic module according to claims 1 to 3, characterized in that the support profile (121, 123, 125) is designed as an extruded profile.

6. Photovoltaic module according to one of the preceding claims, characterized in that the support profile (121, 123, 125) is a trapezoidal profile or an omega profile (Q-profile).

7. Photovoltaic module according to one of the preceding claims, characterized in that the support profile (121, 123, 125) has one or more openings (149) along the longitudinal axis (181) of the support profile and / or has one or more interruptions, wherein the opening (149) or openings (149) and / or the interruption or interruptions are located in the first profile leg (135) and / or in the second profile leg (139).

8. Photovoltaic module according to one of the preceding claims, characterized in that the protective structure (201, 205) has a front protective cover (201) and / or a rear protective cover (205), wherein the front protective cover (201) and / or the rear protective cover (205) is formed in particular from glass (201, 205) with a thickness of less than 3 mm, less than 2 mm, less than 1.5 mm or less than 1 mm.

9. Photovoltaic module according to one of the preceding claims, characterized in that an adhesive (155) , in particular a double-sided adhesive tape , is applied to the mounting surface (131) or to the mounting surfaces (131).

10. Photovoltaic module according to one of the preceding claims, characterized in that a cable provided for forming the electrical connection on the photovoltaic module has a length which is greater than the distance of a connection point of the cable on the photovoltaic module to each edge region of the photovoltaic module, so that each edge region of the photovoltaic module is reachable by means of the cable.

11. Photovoltaic system, in particular wall-mounted power plant or roof-mounted power plant, with one or more photovoltaic modules (101) according to one of the preceding claims 1 to 10, wherein the photovoltaic module or the photovoltaic modules are connected to a substrate (171) at the mounting surface (131) or at the respective mounting surfaces (131).

2. Method for mounting a photovoltaic module (101) according to any one of the preceding claims 1 to 10 on a substrate (171) , comprising the following steps: - Providing the photovoltaic module (101) so that the photovoltaic module (101) is provided with accessible mounting surface (131) or with accessible mounting surfaces (131), - Applying an adhesive (155), in particular a double-sided adhesive tape, to the mounting surface (131) or to the respective mounting surfaces (131), such that the adhesive (155), in particular the double-sided adhesive tape, is applied to the mounting surface (131) or to the mounting surfaces (131), - Applying the photovoltaic module (101) to the substrate (171) with the mounting surface (131) provided with adhesive (155), in particular with the double-sided adhesive tape, or with the mounting surfaces (131) provided with adhesive (155), in particular with the respective double-sided adhesive tape, such that the adhesive (155), in particular the double-sided adhesive tape, is arranged to adhere between the mounting surface (131) or the mounting surfaces (131) and the substrate (171), - Curing of the adhesive (155) and / or adhesion of the double-sided adhesive tape, so that the adhesive (155), in particular the double-sided adhesive tape, firmly connects the respective mounting surface (131) to the substrate (171), so that the photovoltaic module (101) is mounted on the substrate (171).

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