Mounting system, in particular for solar modules
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional mounting profiles for solar modules on roofs and walls, such as open aluminum profiles, often lack optimal strength properties, are prone to deformation, and are costly and difficult to transport and assemble, especially on sloping surfaces.
Innovation Solution
A closed hollow box carrier profile with spaced-apart longitudinal grooves for secure fastening of solar modules and roof attachments, utilizing a click-on system with shaped pieces and webs for form-fitting connections, allowing for efficient assembly and material reduction while maintaining strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If open profiles with multiple webs are used to enable fastening means to grab and find counter bearing, then the mounting system can accommodate modules with different thickness dimensions, but the strength properties deteriorate and the legs or webs easily bend when improperly loaded
Solution Approach 1:
The mounting profile is divided into modular components: a closed hollow box carrier profile with longitudinal grooves for connection, and separate clamping parts with shaped pieces that can be attached as needed. This segmentation allows the main carrier to maintain optimal closed-profile strength while the attached clamping parts provide the necessary adaptability for different module thicknesses.
Solution Approach 2:
The connection system transitions from relying on the profile's cross-sectional geometry (2D web structure) to utilizing longitudinal grooves running along the profile length (1D extension). The shaped pieces with webs engage these grooves, creating a three-dimensional connection system that maintains strength while providing adaptability.
2Reliability
If special profiles with inwardly cranked U-profiles or additional bearing surfaces are used to enable proper fastening, then the mounting function is improved, but the production price increases and the profiles are difficult to bundle during transport
Solution Approach 1:
Instead of making the carrier profile complex with special geometries, the invention inverts the approach by keeping the carrier profile simple (closed hollow box) and adding the functional complexity to the attached clamping parts. The shaped pieces with opposing webs provide the necessary mounting functionality without complicating the main carrier structure.
Solution Approach 2:
The clamping parts are designed to be self-attaching to the carrier profile through the click-on system with shaped pieces engaging longitudinal grooves. This self-service design eliminates the need for complex integrated features in the carrier profile, simplifying manufacturing and transport while maintaining reliable mounting function.
3Strength
If a closed hollow box carrier profile is used to enhance strength properties, then the resistance to deformation is improved, but additional connection features must be added to enable fastening of solar modules and roof attachments
Solution Approach 1:
The connection features are extracted from the carrier profile itself and implemented as separate, removable clamping parts. The longitudinal grooves in the closed hollow box profile provide the interface, while the shaped pieces with webs are attached as needed, separating the structural function from the connection function.
Solution Approach 2:
The closed hollow box carrier profile with longitudinal grooves serves as a universal base structure that can accommodate different clamping parts for various mounting requirements. The same carrier profile can be used with different shaped pieces to adapt to different module types, thicknesses, and roof attachment needs.
4Weight of moving object
If material reduction of 30-40% is achieved through the closed profile design, then the weight and cost are reduced, but the assembly process must be simplified to maintain efficiency on sloping surfaces
Solution Approach 1:
The clamping parts are pre-assembled with shaped pieces that are designed to engage the longitudinal grooves in a single downward motion. This preliminary preparation of the connection mechanism allows for quick installation on sloping surfaces without requiring complex assembly steps during installation.
Solution Approach 2:
The traditional mechanical fastening system requiring multiple steps (drilling, screwing, bolting) is replaced with a click-on system where shaped pieces with webs engage longitudinal grooves through elastic deformation and form-fit connection. This substitution dramatically simplifies the assembly process while maintaining secure fastening.
Data Source
Figure 1
Figure 2
AI summary
The invention relates to a mounting system, in particular for solar modules (1), consisting of brackets (2) with a closed hollow box bracket profile (3), with connectors (4) for solar module fastening means, and connectors (5) for cover fastening means. At least the connectors (4) for the solar module fastening means are formed from longitudinal groove- or longitudinal flange pairs in or on the hollow box bracket profile (3) that are arranged at a distance from each other. The fastening means for the solar module (1) or solar modules (1) in the area of the bracket consist of a tensioning piece with a molded component (8), with each molded component (8) having at least two flanges (9.1, 9.2), arranged opposite each other on the molded part (8) by means of the distant ends from the molded piece (8), of which at least one positive click connection with one of the groove- or flange pairs can be made, and the molded piece (8) has at least one bore hole (11) for the insertion of a fastening bolt (14). The fastening can be carried out as an in- and/or out-click system.