Method for mounting solar modules
The method of forming frustoconical collars in mounting rails simplifies and secures the attachment of solar modules by integrating fasteners, addressing the complexity and adjustability issues of existing methods.
Patent Information
- Authority / Receiving Office
- WO · WO
- Patent Type
- Applications
- Current Assignee / Owner
- IDEEMATEC DEUTSCHLAND GMBH
- Filing Date
- 2025-12-05
- Publication Date
- 2026-06-18
AI Technical Summary
Existing methods for mounting solar modules on rails are complex and time-consuming due to the need for precise alignment of cutouts and create permanent connections that are difficult to adjust.
A method involving the introduction of receiving openings with smaller diameters in the mounting rail, followed by forming frustoconical collars, which are compressed to secure pin-shaped fasteners, allowing for easy alignment and secure fixation of solar modules without the need for precise alignment.
Facilitates quick and secure attachment of solar modules by integrating fasteners into the mounting rail, simplifying the assembly process and enabling easy adjustment of module positions.
Smart Images
Figure EP2025085682_18062026_PF_FP_ABST
Abstract
Description
[0001] December 5, 2025
[0002] Ideamatec Deutschland GmbH S / IDE-020-WO
[0003] Methods for mounting solar modules
[0004] The present invention relates to a method for mounting at least one solar module on a mounting rail of a support device.
[0005] Support structures for solar modules are well-known from the prior art. These support structures typically include mounting posts that are anchored in the ground. These mounting posts are usually connected to one or more longitudinal beams via fixing devices. Mounting rails are generally arranged transversely to these longitudinal beams, and the solar modules are mounted on these rails. The mounting rails are typically connected to the frames of the solar modules.
[0006] When mounting the solar modules on the mounting rails, the usual procedure is to position recesses in the mounting rails and the solar module frame one above the other, in order to then guide fasteners, especially mounting screws, through these recesses to fix the solar modules to the mounting rails.
[0007] One disadvantage of this approach is that the installers must precisely align the cutouts in the module frames and mounting rails in order to insert common fasteners through the overlapping cutouts. This procedure is complex and time-consuming.
[0008] Besides screwing the module frames to the mounting rails, it is also known to connect the module frames and mounting rails using rivets. In addition to the problem described above, this method has the further disadvantage that precise centering of the solar modules on the mounting rails is very difficult. Riveting creates a permanent connection. Once the first rivet is in place, the riveted joint cannot be undone, making it virtually impossible to adjust the position after the first rivet has been set.
[0009] The present invention aims to overcome the disadvantages of the prior art. In particular, the present invention aims to enable the uncomplicated and secure fixing of solar modules to mounting rails of a support device.
[0010] This object is achieved according to the invention by a method having the features of claim 1 and a fastening rail having the features of claim 8.
[0011] By combining steps a) and b) of the inventive method, in which receiving openings with a smaller diameter than the fasteners are first introduced into the mounting rail, and then collars, in particular frustoconical collars, are formed by widening the receiving openings, the basis for a secure hold of pin-shaped fasteners is created. A secure hold of the previously inserted fasteners is achieved by reducing the diameter of the receiving openings through compression of the collars, with the pin-shaped fasteners partially protruding from a module mounting plane of the mounting rail. These connecting sections of the fasteners protruding from the module mounting plane then only need to be guided through the recesses in the frame of the solar modules.This eliminates the need for an installer to meticulously align the connection openings in the module frame and the mounting rail with millimeter precision. In the inventive method, the fasteners are already integrated into the mounting rail, so the module frames simply need to be attached to the connecting sections of the fasteners.
[0012] Advantageously, the punch element is at least partially conical in shape, so that the resulting collars are preferably frustoconical. Such collars interact optimally with fasteners having a round cross-section. Advantageously, the pin-shaped fasteners are metal pins or bolts. In a particularly preferred variant of the process, the pin-shaped fasteners are rivets, especially blind rivets. When using blind rivets, the rivet sleeves correspond to the connecting sections that are passed through the recesses in the module frame during process step e). The section projecting from the lower plane, away from the module support plane, is the mandrel in the case of blind rivets.When using blind rivets advantageously, each rivet, with its rivet sleeve first, is inserted through the narrow end of the respective frustoconical collar until the rivet head contacts the collar in the mounting rail. The compression of the frustoconical collars, as described in step d), is achieved by pressing the rivet heads onto the collars. This is preferably done using a tool designed to hold the mandrel of a blind rivet and apply pressure to the rivet head. Pressing on the rivet head flattens the frustoconical collars, thereby reducing the diameter of the receiving openings. This ensures that the blind rivet is firmly fixed in the mounting rail.
[0013] As a rule, the fasteners are fixed in their final position after step e) has been completed. When using blind rivets as fasteners, they are tightened with a riveting tool. First, the mandrel is pulled, which compresses the rivet sleeve. Finally, the mandrel is removed. This can be done, for example, by snapping it off. To facilitate this, the mandrel may have a predetermined breaking point.
[0014] The mounting rail is usually a profile rail, in particular a top-hat rail with a central cut-off and two side tabs, wherein the two tabs of a mounting rail preferably support two solar modules positioned adjacent to each other, so that one solar module is supported by two mounting rails positioned adjacent to each other.
[0015] DIN rails have the advantage, among others, that two solar modules positioned next to each other can be attached to one and the same rail.
[0016] The mounting rail is usually made of metal, especially aluminum or iron.
[0017] The present invention further relates to a mounting rail for mounting at least one solar module, comprising at least two pin-like fastening means passing through receiving openings in the mounting rail, each with an upper connecting section projecting from a support plane of the mounting rail and a lower fixing section.
[0018] The advantages of the fastening rail according to the invention have already been explained within the context of the method according to the invention.
[0019] Advantageously, the fasteners are metal pins or metal bolts, preferably blind rivets, with the connecting sections being rivet sleeves and the fixing sections being mandrels.
[0020] Further features of the invention will become apparent from the following description of preferred embodiments of the invention in conjunction with the drawings and the dependent claims. The individual features can be implemented individually or in combination with one another.
[0021] The drawings demonstrate a method according to the invention. Specifically, they show:
[0022] Figures 1a to 1c: a mounting rail with pre-installed mounting holes;
[0023] Figures 2a to 2d: enlarged representation of a receiving opening as well as a blind rivet and formation of a truncated cone-shaped collar;
[0024] Figures 3a, 3b: Mounting rail with frustoconical collars;
[0025] Figures 4a to 4c: Inserting blind rivets into the receiving holes of the mounting rail; Figures 5a to 5e: Securing the blind rivets by pressing together the frustoconical collars;
[0026] Figures 6a to 6c: Connecting the mounting rail to a solar module;
[0027] Figures 7a, 7b: Section of a solar power system with mounting rails according to the invention.
[0028] In the following, identical or functionally equivalent elements are marked with the same reference symbols.
[0029] Figure 1a shows a perspective view of a mounting rail in the form of a top-hat rail 1 for use in a method according to the invention and for manufacturing a mounting rail according to the invention. Figure 1b shows the mounting rail 1 in a front view. The top-hat rail 1 comprises a U-shaped central section 2 and two tabs 3 adjoining the respective ends of the central section. The ends of the two tabs 3 each have a bend 4. The tabs 3 form an upper module support plane 5 and a lower fixing plane 6 facing away from plane 5. A total of four receiving openings in the form of circular bores 7 are already provided in the tabs 3 of the top-hat rail 1. Figure 1c shows one of the bores 7 with a diameter dl. In the present embodiment, the top-hat rail 1 is made of stainless steel.
[0030] Figures 2a to 2d demonstrate step b) of the inventive method. Figure 2a shows a section of the DIN rail 1 in the area of a bore 7 with diameter dl. The bore 7 is then machined using a punch element 8, which has a conical end 9, by pressing the punch element 8 with its conical end 9 into the bore 7, as also shown in Figure 2a. This pressing of the punch element 8 into the bore 7 results in the formation of a crater-like, truncated cone-shaped collar 10 in the DIN rail 1. This collar 10 originates from the fixing plane 6 of the tab 3 and extends alongside the central section 2 of the rail 1. The collar 10 has a lower end 11, which now defines the edge of an enlarged opening 7' with diameter d2.The opening 7', located below the fixing plane 6, has a larger diameter d2 than the original bore 7 with diameter dl. The upper end 12 of the collar 10 defines the opening 7" lying in the fixing plane 6, which has a larger diameter than the opening 7'. The collar 10 has a height h. This height of the collar is determined by the pressing force of the punch element 8 and by the diameter of the conical end 9 of the punch element 8.
[0031] Figure 2b shows a pin-shaped fastener in the form of a blind rivet 13. The blind rivet 13 comprises a rivet sleeve 14, a rivet head 15, and a pull tab 16. The rivet sleeve 14 has a diameter dl+ which is slightly larger than the diameter dl of the bore 7. The rivet head has a diameter and height suitable to completely or at least mostly cover the collar 10.
[0032] Figures 2c and 2d show the collar 10 with openings 7' and 7" .
[0033] Figure 3a shows a perspective view of the top-hat rail 1 with four collars 10, which extend downwards from the fixing plane 6 towards the base section 17 of the center from section 2 of the rail 1. In the front view of the rail 1 shown in Figure 3b, the crater-like or truncated cone-like shape of the collars 10 is clearly visible.
[0034] Figures 4a to 4c now demonstrate step c) of the method according to the invention. In this step, the lifting rail 1 is preferably first positioned so that the collars 10 project upwards and the module support surface 5 points towards the ground. Four blind rivets are then inserted into the respective receiving openings 7' in the ends 11 of the collars 10 with their rivet sleeves 14 leading the way, so that the blind rivets 13 extend through the collars 10. The blind rivets 13 are thus pushed through the narrow end 11 of the collars 10 until the rivet heads 15 of the blind rivets 13 contact the respective collar 10 and rest on it (see Figures 4b and 4c).
[0035] Figures 5a to 5e now demonstrate step d) of the method according to the invention. In the present embodiment, a pressing tool 18 is first placed onto the mandrel 16 of a first blind rivet 13 until a lower end 19 of the pressing tool 18 contacts the rivet head 15. The lower end 19 of the pressing tool 18 has a recess 20 corresponding to the outer contour of the rivet head 15. A receiving channel 21 for receiving the mandrel 16 adjoins the recess 20. Finally, the pressing tool 18 is pressed down onto the rivet head 15, which causes the rivet head 15 to be pressed onto the fixing plane 6. This also compresses the collar 10, which in turn reduces the diameter d2 of the narrow end 11 of the collar 10 again so that it corresponds approximately to the diameter dl of the original bore 7.This, in turn, ensures that the blind rivet 13 is now firmly fixed in the tab 3 of the DIN rail 1. In this state, which also represents the state of the now completed rail 1' according to the invention, the mandrel 16 extends from the fixing plane 6 towards the base section 17 of the center of section 2 of the rail 1'. In contrast, the rivet sleeve 14 extends from the module support plane 5 of the tab 3 in the opposite direction. These sections formed by the rivet sleeves 14 of the blind rivets 13 also serve to significantly simplify and facilitate the subsequent assembly of solar modules. This final step e) of the inventive method is demonstrated with reference to Figures 6a to 6c.
[0036] First, the DIN rails 1' according to the invention are mounted on a crossbeam 23 of a solar module support device 24. In the present embodiment, the DIN rails 1' are mounted transversely to the crossbeam 23. The rails 1' are fixed to the crossbeam 23 such that the base sections 17 of the center sections 2 rest on the crossbeam 23. The two rails 1' shown in Figure 6A are mounted at such a distance from each other that a solar module 25 can be placed with its frame 26 on the two tabs 3 of the rails 1', which are arranged adjacent to each other. The frame 26 of the solar module 25 has four recesses 27 for receiving the rivet sleeves 14 of the blind rivets 13. Two recesses 27 are arranged in each of two opposing frame members 28a, 28b.The distance between two recesses 27 in a frame rail 28a, 28b corresponds exactly to the distance between two blind rivets 13 in a tab 3 of a rail 1'. Therefore, an installer only needs to place a solar module onto two adjacent rails 1' such that the respective rivet sleeves 14 in the adjacent rails 1' are inserted into the respective recesses 27 in the frame 26 of the solar module 25. This is illustrated in Figures 6A and 6B. Finally, the blind rivets 13 are tightened using a riveting tool. To tighten a blind rivet 13, the mandrel 16 of the blind rivet 13 is pulled. This causes the rivet sleeve 14 to compress, and at the end of the tightening process, the mandrel 16 is either broken off or cut off. The final fixing of the solar module 25 to the rails 1' is shown in Figure 6c.
[0037] Figure 7a shows a section of a solar power system according to the invention with DIN rails 1' according to the invention. As can be clearly seen here, a single solar module 25 is attached to two adjacent rails 1'. This also illustrates that the two tabs 3 of a single rail 1' support two solar modules 25 positioned side by side.
[0038] Figure 7b shows a schematic representation of a solar power system according to the invention. The two solar module strings shown here each comprise a crossbeam 23 and mounting posts 29, which are anchored in the ground. As can be clearly seen in Figure 7a, the mounting posts 29 are coupled to the crossbeam 23 via a fastening element 30.
Claims
December 5, 2025 Ideamatec Deutschland GmbH S / IDE-020-WO Patent claims 1. A method for mounting at least one solar module (25) on a mounting rail (1') of a support device (24), comprising the following steps: a) providing receiving openings (7) in a mounting rail (1) for the passage of pin-shaped fasteners (13), wherein the diameter dl of the receiving openings (7) is smaller than the diameter of at least one section (14) of the fasteners (13); b) pressing a punch element (8) into the receiving openings (7) to enlarge the diameters of the receiving openings (7) and to create a collar (10) in each case; c) inserting the fasteners (13) into the enlarged receiving opening (7') such that the fasteners (13) extend through the receiving openings (7'); d) reducing the diameters of the receiving openings (7') by compressing the collars (10);e) Placing the solar module (25) to be mounted onto the mounting rail (1'), wherein at least part of the connecting sections (14) of the fastening means (13) projecting from a module support plane (5) of the mounting rail (1') are passed through recesses (27) in a frame (26) of the solar module (25).
2. Method according to claim 1, characterized in that the fastening means are metal pins or metal bolts, preferably rivets, in particular blind rivets (13).
3. Method according to claim 2, characterized in that the fastening means are blind rivets (13) with rivet heads (15), wherein each blind rivet (13) is inserted with its rivet sleeve (14) forward through the narrow end (11) of the collar (10) until the rivet head (15) of the blind rivet (13) contacts the corresponding collar (10).
4. Method according to claim 3, characterized in that the collars (10) are pressed together by pressing the rivet heads (15) of the blind rivets (13) onto the jugs (10).
5. Method according to one of the preceding claims, characterized in that the punch element (8) is at least partially conical in shape, wherein the collars (10) produced with the punch element (8) are in particular frustoconical in shape.
6. Method according to one of the preceding claims, in particular according to claim 2, characterized in that the fastening means (13) are fixed in their final position after step e), in particular the fastening means designed as blind rivets (13) are tightened with a riveting tool.
7. Method according to one of the preceding claims, characterized in that the mounting rail is a profile rail, in particular a top-hat rail (1, 1') with a central section (2) and two lateral tabs (3), wherein the two tabs (3) of a mounting rail (1') preferably support two solar modules (25) positioned adjacent to each other, such that one solar module (25) is supported by two mounting rails (1') positioned adjacent to each other.
8. Method according to one of the preceding claims, characterized in that the fastening rail (1, 1') is made of metal, in particular aluminium, or iron, in particular steel or stainless steel.
9. Mounting rail (1, 1') for mounting at least one solar module (25), comprising at least two pin-like fastening elements (13) extending through receiving openings (7) in the mounting rail (1'), each with an upper connecting section projecting from a module support surface (5) of the mounting rail (1'). (14) and a lower fixation section (16).
10. Fastening rail according to claim 9, characterized in that the fastening means are metal pins or metal bolts, preferably blind rivets (13), wherein the connecting section is rivet sleeves (14) and the fixing sections are pull mandrels (16).
11. Solar system comprising a plurality of support posts (29), at least one crossbeam (23) and a plurality of solar modules (25), characterized in that the solar modules (25) are mounted on mounting rails (1') according to one of claims 9 or 10, wherein the solar modules (25) have receiving openings (27) for receiving the connecting sections (14) of the fastening means (13).