Deformation-preventing connection apparatus

Abstract

The present invention relates to a robust and easily mountable connection apparatus that is developed to prevent the tearing of membrane parts and maintain waterproofing after solar energy panels are mounted on membrane roofs. Waterproof membrane roofs are perforated to install solar panels and similar components using mounting apparatuses. To preserve the waterproofing property, membrane protection (5) is placed over the connection point. Preventing the connection elements from puncturing or tearing membrane protection (5) is crucial for maintaining the waterproofing integrity. Thanks to the present invention, when pressure is applied to a soft and flexible insulation material (3) and it is compressed, the connection element (8a) does not damage the membrane protection (5).

Description

[0001] PATENT DESCRIPTION

[0002] DEFORMATION-PREVENTING CONNECTION APPARATUS

[0003] Technical Field

[0004] The present invention relates to a robust and easily mountable connection apparatus that is developed in order to prevent the tearing of membrane parts and maintain waterproofing after solar energy panels are mounted on membrane roofs.

[0005] Waterproof membrane roofs are perforated to install solar panels and similar components on them by using mounting apparatuses. In order to preserve the waterproofing property, a membrane piece is placed over the connection point. To prevent the connection elements, which provide the connection with the roof, from puncturing or tearing the membrane piece is crucial for maintaining the waterproofing integrity. Thanks to the present invention, when pressure is applied to a soft and flexible insulation material and it is compressed, the connection element does not damage the membrane protection.

[0006] State of the Art

[0007] Solar energy panels are systems that convert sunlight into electrical energy. The photovoltaic cells in these panels directly convert sunlight into electric current, helping meet electricity needs in homes, workplaces, and various industrial facilities. Since solar energy is a clean and sustainable energy source, it enables energy production without causing environmental harm compared to fossil fuels. Despite the installation costs, solar panels are becoming increasingly popular as they provide long-term energy savings. Particularly, solar energy panels installed on roofs or large fields help reduce energy costs for both individual users and large facilities.

[0008] The advantages of solar energy panels include their eco-friendliness and their role in making energy sustainable as a renewable resource. Additionally, these panels have an operational lifespan of approximately 25-30 years and can maintain efficiency with regular maintenance. Governments offer incentives to promote the use of solar energy, encouraging more people to adopt this renewable energy source. Consequently, the installation of solar energy panels is becoming widespread, contributing to the reduction of the carbon footprint associated with energy production.Said solar energy panels are utilized in different applications, primarily for electricity generation to reduce energy costs in homes and businesses. Other applications include water heating systems for domestic hot water, irrigation systems, greenhouse heating, electrically powered agricultural equipment, electrification of remote and rural areas without electrical infrastructure, and net metering, where excess energy is fed into the grid.

[0009] In such applications, solar energy systems are placed in large surface areas directly exposed to sunlight. Examples include the roofs or facades of buildings such as homes, businesses, and industrial facilities, as well as infrastructure projects such as sound insulation walls or barriers along highways and railway tracks.

[0010] For many commercial and industrial buildings, installing solar energy panels on roofs presents a viable energy solution. This is especially advantageous in urban areas or regions with limited land use.

[0011] As roofing waterproofing preferences diversify, new mounting methods are increasing. New solution requirements also arise for membrane roofs, which have become a popular option for industrial and commercial buildings. These membrane roofs and their associated insulation materials are typically flexible, lightweight, and relatively soft. Due to these structural properties, membrane roofing systems provide water and air insulation, do not impose significant loads on the structure due to their lightweight nature, and offer resistance to cracking and deformation due to their flexibility.

[0012] However, mounting certain apparatuses on membrane roofs compromises their waterproofing properties, leading to increased water permeability. Additionally, when loads are applied to the roof, the insulation material compresses due to its soft nature. The mechanical connection elements used during installation can rise from their surface positions, causing deformation and tearing in the covering layers. Heavy equipment such as solar energy panels imposes additional loads on the roof, making it difficult for the building and roof to bear these loads structurally.

[0013] Another problem encountered during installation on the roofs is that the mounting apparatuses often contain detailed components, making them expensive and complex to manufacture.

[0014] In the state of the art, Turkish Patent No. TR2024007639 was developed to maintain the waterproofing of membrane roofs and facilitate easy installation. One of the most significantadvantages of this invention is that it is mounted onto the roof using elements such as screws and bolts. This increases the apparatus's strength and enhances its resistance to external forces. However, since the mentioned membrane roofs and insulation materials have a soft structure, areas where pressure is applied develop inclinations. Due to these inclinations, the head of the screw can exert pressure on the membrane covering, leading to tears. As a result, the roof surface loses its waterproofing ability, allowing water to seep into the building.

[0015] In the state of the art, U.S. Patent No. US2010175337A1 discloses systems and methods for efficiently securing a support structure to a roof surface without perforating the roof membrane. In various applications, sliding pads that provide friction and cushioning between the supports and the roof membrane are used. Said sliding pads enable the supports to remain in place on the roof without penetrating the membrane. Said support sits on a sliding pad placed on the roof membrane. Any material that provides sufficient cushioning between the support's lower surface and the top of the roof membrane while being difficult to slide against these surfaces (e.g., EPDM or other elastomers) is suitable. However, while this invention enables attachment without creating holes in the roof, it does not offer the same level of strength and durability as mechanical connections. Particularly under harsh weather conditions, it can deform quickly.

[0016] In the state of the art, U.S. Patent No. US2002046506A1 describes a mounting system for elevating and supporting objects such as solar panels and satellite dishes on roofs. The mounting base includes a long fastener or brace that can be screwed into a roof rafter, requiring a single lag bolt placed directly beneath the brace to secure it. The mounting structure also includes a guide tunnel to ensure the correct drilling angle into the rafter. While this guide tunnel allows the screw to move freely within, it does not address the issue of leakage caused by perforating membrane roofs.

[0017] In previous patents and utility models found in the state of the art, connection apparatuses for mounting solar energy panels onto roofs have been identified. Some of said apparatuses are designed for application on membrane roofs to prevent leakage. However, these known systems consist of complex components that fail to prevent deformations caused by mechanical connection elements, present manufacturing and installation difficulties, and disrupt the visual integrity of the roof. There is a need for systems that maintain the integrity of membrane roofs, resist tearing and deformation, prevent leakage, and offer ease of manufacturing and installation with minimal components.Technical Problems That the Present Invention Aims to Solve

[0018] With the development of the connection apparatus according to the present invention, solar energy panels can be securely mounted on membrane roofs. The apparatus is fixed to the roof by perforating the membrane and using connection elements such as screws or bolts. A membrane piece is placed over the perforation to maintain the roof's water resistance. Since the insulation layer is soft, it compresses under pressure, causing screws or bolts to rise to the surface. To prevent this, the connection elements are placed within a tube. This prevents any damages to the membrane covering placed on top of the connection apparatus and provides long-term protection against issues such as tearing and puncturing.

[0019] The objective of the present invention is to ensure that the equipment such as panels is securely mounted on the roof while preserving the waterproof feature of the membrane roof over the long term.

[0020] The most significant advantage of the present invention is to prevent the mechanical connection elements from protruding to the surface and deforming the membrane piece when pressure is applied to the soft and flexible roof insulation.

[0021] Another significant advantage of the present invention is that it is entirely made of aluminum, preventing contact corrosion. Contact corrosion frequently occurs at the surfaces where profiles come into contact. Since the profiles connected to the present invention are aluminum, the manufacturing of the product entirely from aluminum eliminates the risk of contact corrosion. This ensures long-term durability without structural degradation.

[0022] Another significant advantage of the present invention is to provide ease of manufacturing and installation due to its simple design with minimal parts, thereby reducing costs.

[0023] Since the roof connection is established directly through mechanical attachment rather than bonding two membrane layers together, the membrane is not affected by the wear caused by temperature increases on roof surfaces over the years. Additionally, when mounted at parallel or angled positions, the membrane is not affected by the heat load from the solar panels, ensuring a secure installation.Another advantage of the present invention is that its lightweight structure prevents additional loads on the roof, thereby protecting both the building and the roof.

[0024] Furthermore, another advantage of the present invention is to maintain the visual integrity of the membrane roof.

[0025] Brief Description of the Figures

[0026] Figure 1 is an exploded perspective view of the connection apparatus of the present invention. Figure 2 is a perspective view of the connection apparatus mounted on a roof.

[0027] The reference numbers for sections, parts, and flows in the Figures, which aid in explaining the invention:

[0028] 1. Base

[0029] la. Tie rod slot

[0030] lb. Plastic sleeve tube slot

[0031] lc. Screw slot

[0032] 2. Tie rod

[0033] 2a. Tie rod threads

[0034] 3. Insulation material

[0035] 4. Lamination material

[0036] 5. Membrane protection

[0037] 6. Gasket

[0038] 7. Cap

[0039] 7a. Tie rod hole

[0040] 8. Plastic sleeve tube

[0041] 8a. Connection element

[0042] 9. Roof membrane

[0043] 10. Roof sheetDetailed Description of the Invention

[0044] The present invention is a connection apparatus for solar energy panels that prevents deformation and associated water leakage issues when mounting said panels on membrane roofs, ensuring easy and secure installation. The invention is cost-effective due to its simple design with minimal parts.

[0045] The connection apparatus of the present invention has been developed for mounting solar energy panels onto membrane roofs. To ensure secure installation, solar energy panels are mounted by perforating membrane roofing systems. If solar panels are not securely mounted on inclined or flat roofs, they may fall due to inclination or wind. The mentioned membrane roofing systems are waterproof, and any perforation during installation compromises this feature. The connection apparatus of the present invention ensures the preservation of waterproofing. One of its most important features is that the connection elements (8a) do not puncture or tear the membrane protection (5). When pressure is applied to the soft and flexible insulation material (3), the connection element (8a) does not damage the membrane protection (5) even when compressed.

[0046] In Figure 1, an exploded perspective view of the connection apparatus of the present invention is illustrated. According to the Figure 1, said connection apparatus fundamentally comprises:

[0047] At least one base (1), which is a surface that provides connection of the apparatus to the roof, wherein there is at least one tie rod slot (la);

[0048] At least one tie rod (2) that extends upward from the base (1) by passing through the tie rod slot (la) on the base (1), which is used to connect aluminum profiles, supporting solar energy panels;

[0049] At least one plastic sleeve tube slot (lb) on said base (1);

[0050] At least one plastic sleeve tube (8), which is connected to the base (1) by inserting from the upper part of the plastic sleeve tube slot (lb) to downward and extended to downward of the base (1) through the insulation material (3) to ;

[0051] At least one connection element (8a), which is placed within the plastic sleeve tube (8), capable of moving vertically in said plastic sleeve tube (8) and provides mechanical connection to the roof sheet (10);

[0052] At least one membrane protection (5), which is positioned over the tie rod (2) and provides to maintain waterproofing and visual integrity of the membrane roof;At least one lamination material (4) that is placed between the base (1) and membrane protection (5), which is characterised by double-sided adhesive and waterproof properties,; At least one gasket (6), which is positioned over the membrane protection (5) to ensure liquid insulation;

[0053] At least one cap (7) that secures all elements together, wherein said gasket (6) is inserted through it and the tie rod (2) is inserted and exits.

[0054] The base (1) according to the present invention is preferably made of 4 mm thick aluminum. Since the profiles connected to the base (1) are also made of aluminum, this structure prevents contact corrosion.

[0055] There is the plastic sleeve tube slot (lb) on the base (1) that provides easiness in mounting the base (1) onto the roof by using a connection element (8a), such as a screw or bolt. Thanks to said plastic sleeve tube slot (lb), it is not required to perforate the base (1) additionally during mounting to the roof; it is taken to the installation site with ready slots and mounted. There is the screw slot (lc) on the base (1). Said screw slot (lc) enables universal use in cases where tubes cannot be used, such as in combination panel installations where the roof membrane (9) has a metal sheet underneath. The tie rod slot (la) in the base (1) has a square shape, preventing the tie rod (2) from rotating by fitting into a corresponding square recess under its head.

[0056] Said plastic sleeve tube slot (lb) accommodates a plastic sleeve tube (8) extending downward. The connection element (8a) is mounted onto the roof sheet (10) through the said plastic sleeve tube slot (lb). Here, said connection element (8a) is capable of moving upward in the vertical direction. When pressure is applied to the roof, even if the insulation material (3) is compressed, the connection element (8a) does not protrude to the surface and does not damage the membrane protection (5).

[0057] Preferably, four plastic sleeve tube slots (lb), plastic sleeve tubes (8), and connection elements (8a) are included to ensure a strong attachment to the roof, providing resistance to external forces such as wind, rain, or impact.

[0058] The tie rod (2) is connected to the base (1) using methods such as welding, riveting, adhesive bonding, or soldering, and it is also made of aluminum to prevent contact corrosion.In the preferred embodiment of the present invention, a square tie rod slot (la) is formed in the center of the base (1), and the base (1) is positioned upward through the tie rod slot (la). In an exemplary application, the tie rod slot (la) has dimensions of MIO x 80 mm. However, these dimensions may vary depending on modifications made to the profiles. The tie rod (2) has a square recess under its head that fits into the square-shaped tie rod slot (la). Thus, the head of the tie rod (2) settles into the tie rod slot (la), preventing rotation.

[0059] Said tie rod (2) will be used to mount aluminum profiles, and the tie rod (2) comprises tie rod threads (2a) that enable the installation of the profiles. The membrane protection (5), which is placed over the tie rod (2), can be selected in the desired brand, model, and pattern or even matched with the roof membrane (9) to achieve complete visual uniformity and provide a natural appearance.

[0060] The lamination material (4) that is placed between the base (1) and membrane protection (5) can be made of EPDM (Ethylene Propylene Diene Monomer) and in a preferred application, more effective adhesion can be achieved by applying primer on the surface.

[0061] The gasket (6) that is one of the connection apparatus elements, is made of EPDM for increased liquid impermeability.

[0062] The cap (7) that is one of the connection apparatus elements, is also made of aluminum to prevent contact corrosion.

[0063] In a preferred embodiment, said base (1), membrane protection (5), and cap (7) are round shaped, but they can be manufactured in any geometric shape.

[0064] Said cap (7) has a tie rod hole (7a) that extends downward from the top, with open ends, allowing the tie rod (2) to be positioned and holding the components together. The tie rod (2) is inserted by passing through the tie rod hole (7a). Preferably, the tie rod hole (7a) has an MIO internal threaded structure. The bolt system used in the present invention is designed to be removable and reinstallable, allowing for maintenance and renewal while also ensuring a secure connection.Industrial Applicability

[0065] The connection apparatus of the present invention is compatible with all types of roofs covered with TPO, PVC, EPDM, and bituminous membranes in buildings such as houses, workplaces, and industrial facilities. It is particularly suitable for high-inclination roofs requiring strong attachment and for use in windy regions. In addition to solar energy panels, it can also be used for pipe supports, step transitions, electrical trays, satellite antennas, HVAC applications, and similar mounting systems.

Claims

CLAIMS1. A deformation-preventing connection apparatus for mounting solar energy panels onto a membrane roof, characterized by comprising:at least one base (1), which is a surface that provides connection of the apparatus to the roof, wherein there is at least one tie rod slot (la);at least one tie rod (2) that extends upward from the base (1) by passing through the tie rod slot (la) on the base (1), which is used to connect aluminum profiles, supporting solar energy panels;at least one plastic sleeve tube slot (lb) on said base (1);at least one plastic sleeve tube (8), which is connected to the base (1) by inserting from the upper part of the plastic sleeve tube slot (lb) to downward and extended to downward of the base (1) through the insulation material (3) to ;at least one connection element (8a), which is placed within the plastic sleeve tube (8), capable of moving vertically in said plastic sleeve tube (8) and provides mechanical connection to the roof sheet (10);at least one membrane protection (5), which is positioned over the tie rod (2) and provides to maintain waterproofing and visual integrity of the membrane roof; at least one lamination material (4) that is placed between the base (1) and membrane protection (5), which is characterised by double-sided adhesive and waterproof properties,;at least one gasket (6), which is positioned over the membrane protection (5) to ensure liquid insulation;at least one cap (7) that secures all elements together, wherein said gasket (6) is inserted through it and the tie rod (2) is inserted and exits.

2. A connection apparatus according to Claim 1, characterized in that said base (1) comprises at least one screw slot (lc) that facilitates mounting the base (1) to the roof using a connection element (8a), such as a screw or bolt.

3. A connection apparatus according to Claim 1, characterized in that the tie rod (2) has an externally threaded structure, and said cap (7) has an internally threaded tie rod hole (7a).

4. A connection apparatus according to Claim 1, characterized in that said cap (7) is made of aluminum.

5. A connection apparatus according to Claim 1, characterized in that said tie rod (2) is made of aluminum.

6. A connection apparatus according to Claim 1, characterized in that said base (1) is made of aluminum.

7. A connection apparatus according to Claim 1, characterized in that said base (1), membrane protection (5), and cap (7) have a circular shape.

8. A connection apparatus according to Claim 1, characterized in that said gasket (6) and lamination material (4) are made of EPDM.

9. A connection apparatus according to Claim 1, characterized in that it comprises a square- shaped tie rod slot (la).

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