Interlocking Roof Crossbeam Assembly for Rainproof PV Module Mounting
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Solution Overview
Problem
Current fastening systems for photovoltaic modules on pitched roofs require additional sealing materials and custom-made products due to shading issues, increasing production costs and complexity, especially for large-area laminates used in in-roof installations.
Innovation Solution
The fastening system features interlocking profiles on eaves-side and ridge-side crossbeams with a U-shaped bracket and support structure, creating a rainproof connection without additional sealing, allowing for prefabricated modules with ventilation and drainage, and using plastically deformable materials for sealing, enabling easy installation and reducing shading.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If scale-like overlapping installation is used in the longitudinal direction, then rainproof connection is achieved, but additional sealing materials are required and production costs increase
Solution Approach 1:
The sealing function is merged into the crossbeam structure itself through the interlocking profiles. The eaves-side crossbeam's bracket and projection, together with the ridge-side crossbeam's extension, form an integrated sealing system that eliminates the need for separate sealing materials while maintaining rainproof connection.
Solution Approach 2:
The coordinated interlocking profiles act as an intermediary mechanism between adjacent modules. The bracket, projection, and extension work together as a mediating structure that provides both mechanical connection and sealing function, replacing traditional separate sealing components.
2Reliability
If additional sealing materials are used, then rainproof connection is ensured, but device complexity and installation complexity increase
Solution Approach 1:
The sealing function is integrated into the structural crossbeams themselves. The interlocking profiles of the eaves-side and ridge-side crossbeams combine mechanical support and sealing functions in a single system, reducing device complexity while ensuring rainproof connection.
3Object-generated harmful factors
If custom-made products are produced for in-roof installation, then shading is avoided, but production costs increase
Solution Approach 1:
The fastening system with coordinated interlocking profiles is designed to be universal and adaptable to different module configurations. The same basic crossbeam structure with bracket-projection and extension profiles can be used for both on-roof and in-roof installations, eliminating the need for custom-made products while avoiding shading issues through proper interlocking design.
4Loss of time
If prefabricated modules are used, then installation time is reduced, but manufacturing complexity increases
Solution Approach 1:
The system is segmented into modular crossbeam units with standardized interlocking profiles. Each crossbeam assembly can be pre-fabricated with its bracket, projection, and extension components, then quickly assembled on-site by simply engaging the interlocking profiles, reducing installation time while keeping manufacturing complexity manageable through standardization.
Data Source
Figure 1~2
Figure 3
AI summary
The invention relates to a fastening system for a plate-shaped structural element (12, 44) on a pitched roof, wherein the plate-shaped structural element (12, 44) is bordered in a water-tight manner by a frame and fully replaces the roof covering, and wherein the cross beams (10, 40) of the frame on the eaves side and the ridge side extending transversely to the ridge-eaves direction have profiles that are matched to each other and engage in each other. In order to also use large-surface-area photovoltaic laminates for in-roof setting, the eaves side cross beam (10) may on the upper side thereof have a mounting (18) that surrounds the edge of the plate-shaped structural element (12) in a U-shaped manner and on the bottom side thereof a support (14) for fastening to the roof construction, comprising a strut (26) that extends from the lower limb (22) of the mounting (18) to the support (14), a protrusion (28) extending from beneath the mounting (18) such that between the mounting (18) and the protrusion (28) a channel (30) is created, which during the installation of a second module close to the eaves receives an extension (48) extending from the ridge side cross beam (40) thereof.