Device and method for fixing a support structure for a solar panel to a corrugated roof
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Solution Overview
Problem
Current solutions for fixing solar panels to corrugated roofs using screw connections face issues such as leakage, weakened roof structure, and alignment challenges due to the non-linear nature of corrugated roofs, where screws in valleys can cause water ingress and those at crests compromise the roof's strength.
Innovation Solution
A device with a base element, partially resilient first and second legs, and a top structure that forms a receiving space for the corrugated roof crest, allowing deformation to distribute weight through valley regions, providing stable engagement and easy alignment, and incorporating a sealing element for waterproofing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If screw connections are positioned in the valleys of the corrugated roof plate, then alignment of the support rails is facilitated, but leakage is likely to occur due to rainfall flowing through the valleys
Solution Approach 1:
The device is divided into a base element for fastening and a separate top structure for support rail coupling, with the aperture positioned in the valley region. This segmentation allows the fastening function to occur at the valley (facilitating alignment) while the top structure provides overhead protection to prevent leakage into the screw connection.
Solution Approach 2:
The top structure acts as an intermediary element between the support rail and the base element in the valley. It provides a protective overhead cover that prevents rainfall from directly reaching the screw connection in the valley, thus preventing leakage while maintaining alignment benefits.
2Object-affected harmful factors
If screw connections are positioned at the crests of the corrugated roof plate, then leakage is prevented, but the strength of the corrugated roof plate and the entire construction is negatively affected
Solution Approach 1:
The device separates the fastening function (base element in valley) from the support function (top structure at crest), allowing the screw connection to be positioned in the stronger valley region while the top structure provides support at the crest, thus maintaining both strength and leakage prevention.
Solution Approach 2:
Different parts of the device are positioned at different locations with different functions: the base element with aperture is positioned in the valley where strength is higher and alignment is easier, while the top structure extends to the crest area to provide support and overhead protection, optimizing both structural integrity and leakage prevention.
3Strength
If standard screw connections are used on corrugated roofs, then fixation is achieved, but the screws are likely to get skewed due to the non-linear structure resulting in a less rigid construction
Solution Approach 1:
The base element is designed with the aperture positioned in the valley region where the corrugated roof has a more linear and stable structure, creating an equipotential position that is easier to align and less prone to skewing, thereby improving construction rigidity and ease of installation.
4Strength
If a receiving space for the crest is defined by the base element and legs, then stable engagement and load distribution are achieved, but the device complexity increases
Solution Approach 1:
The base element and the top structure are merged into a single integrated device that simultaneously provides fastening (base element in valley) and support (top structure at crest), achieving stable engagement and load distribution through the receiving space while reducing the need for separate components.
Solution Approach 2:
The device serves multiple functions: the base element provides fastening to the roof, the receiving space engages the crest for stability, the legs provide load distribution to valley regions, and the top structure couples with the support rail and provides overhead protection. This multi-functionality achieves stable engagement and load distribution while maintaining a relatively simple integrated structure.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The device ensures stable and watertight fixation of solar panels by distributing loads through strong valley regions, enhancing structural integrity and simplifying alignment and installation, while preventing water leakage and excessive pressure on weak crest areas.
Implementation Method 1
at least one, at least partially resilient, first leg which is connected to the base element, at least one, at least partially resilient, second leg which is connected to the base element... fastening of the device onto said corrugated roof by means of said fastening element, in particular said fastening screw, will cause deformation of both the at least one first leg and the at least one second leg
Data Source
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AI summary
The invention relates to a device (1) fixing a support structure for at least one solar panel, in particular a support rail (23) of a support structure for at least one solar panel (24), to a corrugated roof (20) comprising at least one corrugated roof plate (21), said device (1) defines a receiving space (7) for receiving at least part of a crest (C) of at least one corrugated roof plate (21) and being configured for co-action with at least one fastening element for fastening of the device (1) onto the corrugated roof (20).