Solar Module Mounting Profile With Click-Lock Box Beam Fastening
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Solution Overview
Problem
Conventional mounting profiles for solar modules on roofs and inclined surfaces, such as aluminum or aluminum alloy profiles, suffer from poor fastening properties, ease of deformation, high manufacturing costs, and difficulties in transportation and installation due to their open design.
Innovation Solution
A closed hollow box girder profile with spaced longitudinal grooves or flanges for click-together connections, providing a positive locking mechanism that prevents movement and includes a bore for fastening, allowing for efficient and secure attachment of solar modules and roof hooks without compromising the profile's strength or increasing its dimensions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If open profiles with multiple webs are used to provide fastening surfaces, then fastening properties are improved, but structural strength and resistance to deformation deteriorate
Solution Approach 1:
The support profile is segmented into a closed hollow box structure with integrated fastening elements (longitudinal grooves or flanges) rather than using separate open webs. This segmentation allows the profile to maintain structural integrity while providing dedicated fastening surfaces through the grooves/flanges that engage with clamping parts.
Solution Approach 2:
The profile structure and fastening elements are merged into a single closed box profile design. The longitudinal grooves or flanges are integrated directly into the profile walls, combining the structural support function with the fastening function in one unified component, eliminating the need for separate open webs.
2Ease of operation
If complex special profiles are used to achieve proper fastening, then fastening properties are improved, but manufacturing cost increases
Solution Approach 1:
The closed box profile serves multiple functions simultaneously: structural support, fastening engagement through integrated grooves/flanges, and a closed chamber for potential cable routing. This multi-functionality eliminates the need for separate fastening components and reduces manufacturing complexity.
Solution Approach 2:
The fastening function is extracted as separate longitudinal grooves or flanges that can be independently formed into the profile wall, allowing standardized manufacturing processes while providing specialized fastening capabilities where needed.
3Ease of operation
If open profiles with multiple webs are used, then fastening surfaces are provided, but resistance to bending and deformation deteriorates
Solution Approach 1:
The profile is segmented into a closed box structure with distinct longitudinal grooves or flanges for fastening, separating the structural box from the fastening elements while maintaining their integration. This segmentation provides both structural stability and dedicated fastening surfaces.
Solution Approach 2:
The closed box profile and fastening surfaces are merged into a unified structure where the grooves or flanges are formed as integral parts of the profile walls, providing both structural integrity and fastening capability without compromising either function.
4Ease of manufacture
If simple profiles are used, then manufacturing cost is reduced, but fastening properties deteriorate
Solution Approach 1:
The simple closed box profile is merged with integrated longitudinal grooves or flanges that provide fastening functionality. This combination maintains the simplicity and low manufacturing cost of the basic profile while adding essential fastening capabilities through the integrated elements.
Solution Approach 2:
The profile design achieves multi-functionality by combining structural support, fastening engagement, and potential cable routing in a single closed box profile with integrated grooves or flanges, eliminating the need for complex separate components.
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 solution offers improved fastening properties, reduced material usage by 30-40% while maintaining strength, enabling easier installation, improved stackability, and cost-effectiveness by eliminating the need for complex profiles, allowing for secure and efficient mounting on inclined surfaces.
Implementation Method 1
at least the connectors for the solar module fastening means are formed of spaced apart longitudinal groove or longitudinal flange pairs within or on the box girder profile and the opposing webs positioned on the shaped part engage with their ends remote from the shaped part respectively into one longitudinal groove of the longitudinal pair or over a longitudinal flange of a longitudinal flange pair of the support
Implementation Method 2
the positive connection can also be paired with a frictional connection with the corresponding construction of the flange/groove
Data Source
AI summary
The invention relates to a mounting system, in particular for solar modules (1), consisting of supports (2) with a closed hollow box profile (3), with connectors (4) for solar module fastening means, and connectors (5) for roof fastening means. At least the connectors (4) for the solar module fastening means are formed from longitudinal groove pairs—or longitudinal flange pairs in or on the hollow box 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 support consist of a clamping piece with a shaped part (8), with each shaped part (8) having at least two webs (9.1, 9.2), arranged opposite each other on the shaped part (8) whereby at least one positive click connection with one of the groove pair—or flange pairs can be made by means of the ends remote from the shaped part (8), and the shaped part (8) has at least one bore hole (11) for the insertion of a fastening bolt (14). The fastening can be carried out as a click-in and/or click-on system.