Patent Application
20160231026
This application claims the benefit of priority of prior European application No. 13004752.5 filed on Oct. 2, 2013, and the entirety of this application is expressly incorporated herein by reference in its entirety and as to all its parts, for all intents and purposes, as if identically set forth in full herein.
The invention relates in general to a mounting system for plate-like members, also called panels, such as solar modules, solar collectors, hybrid collectors, esthetical elements or any combination thereof. The invention is especially suited for frameless solar modules and frameless hybrid collectors. The inventive system may also be used for mounting any other plate-like member especially when the benefits of the invention apply.
The inventive mounting system is especially suited for mounting plate-like members on slanted roofs, especially on top of weather proof roofs, as opposed to building integrated systems where the plate-like members form weather proof roofing. The inventive system is especially designed to be cost-effective, easy to use, to be modular and offer a new way of keeping the plate-like members clean near their bottom edge.
According to the state of the art mounting rails for holding solar panels are known as for example shown in
In the EP 0 905 795 A2 a horizontal mounting rail is disclosed and shown in
Using such a system for frameless panels has the disadvantage that water will collect near the lower bottom edge of the panel. Even if a groove is provided for transporting the water away from the panel, water will collect. Moreover, since the rail, which normally consists of multiple rails placed next to each other, will not be mounted perfectly in one straight line, water will collected in lower portions of the rail. Even if the rails were perfectly straight, the water would have to travel a long way before it could leave the groove.
Wherever water collects, algae, small plants and other life forms will grow and dirt will collect, hindering the transport of the water, thus collecting more water to further stimulate growth of all kinds of life forms.
In the long run the water will not be able to run off as desired and start collecting near the module.
Water may thus penetrate the solar module, since frameless modules often have no edge sealing, meaning that the encapsulant of the module is not covered. Since the most common encapsulants (especially EVA) are hydroscopic, water will enter the module, causing delamination and oxidation of electrical parts. Also the water, life forms and dirt in it may cover the module, leading to shading and thus reduction of electrical and or thermal output.
Cleaning the module will resolve the latter problem, even if this comes at a cost. As will be described in more detail in relation to
It is the goal of the present invention to provide a mounting system, especially for frameless panels, that removes water from the module more readily. By doing so the need for cleaning of the panels and especially the mounting system itself is reduced drastically.
This goal is achieved by letting the water run off the mounting system in a direction perpendicular to the direction the rail extends in. Moreover, a slanted surface is provided, that allows the water to run off in direction of the roof top. A second surface may be provided for letting water run off towards the base of the roof. The surface is slanted relative to the horizontal, so that water runs off readily. Preferably the surface, or actually the parts of the surface defining the water level of water being collected by the mounting system, makes an angle to the horizontal larger than 1° even more preferred larger than 5°.
These goals are met by mounting systems according to the characterizing portions of the independent claims. Further features are defined by the dependent claims, the drawing figures and the detailed description of an embodiment of a mounting system according to the invention.
The new and inventive mounting rail for plate-like elements such as solar panels, in particular for roofs extending in a slanted plane, has roof mounting means for being mounted on that roof and defining a mounting plane as well as an insert mounting recess to receive an edge of a plate-like element for being held in that first insert mounting recess, similar to prior art mounting rails for horizontal use. The mounting recess has a lower and an upper face opposing each other, as is also known.
For meeting the above-mentioned goal the lower face of the insert mounting recess is declining to the outside of the mounting rail forming an angle of at least 11°, preferably an angle of at least 41°, with the upper face and/or the mounting plane, according to the present invention. Thereby, a slanted water run off plane is defined that allows the water to flow to the roof surface in a direction towards a vertical plane containing the top or ridge of the roof. The above-given values are preferred for roofs with angles of inclination between 10° and 40° to provide a water run off plane slanted towards the surface of the roof and away from the insert holding recess. For roofs with other angles of inclination, mounting rails with steeper or less steep lower faces can be provided, as long as the lower face is slanted towards the roof surface at least with an angle of inclination at least 1° or more steeper than a horizontal plane.
Preferred, a plane is defined by the center edge and the outer edge of the lower face of the insert mounting recess, said plane slanted towards the outside of the mounting rail and forming an angle γ of at least 11°, most preferred an angle of at least 41°, with the upper face and/or the mounting plane. Again, said plane is defining the slanted water run off plane for preventing water and dirt to collect near the lower edge of the plate-like elements and flow away in the direction defined in the preceding paragraph.
To be able to hold plate-like elements at their lower edges, but with one and the same mounting rail holding elements adjacent and below the mounting rail, a second insert mounting recess is provided at the side opposite of the insert mounting recess. Although this second recess is depicted being deeper than the first insert mounting recess and is showing a second lower face being wider than the first lower face, embodiments with other dimensions of the second recess and its upper and lower faces are possible. Since the second insert mounting recess is open in the direction downward of the slanted roof, the second lower face can preferred form an angle with the second upper face and/or the mounting plane smaller than the angle of the lower face of the first insert mounting recess.
The mounting rail disclosed in the preceding paragraphs can be further characterized by an upper face of the insert mounting recess that extends mainly parallel to the mounting plane, in particular the side of the roof mounting means facing the roof. Preferred, the second upper face of the second insert mounting recess extends mainly parallel to the roof mounting means or the mounting plane.
While the mounting rail described in the preceding paragraphs can be used with plate-like elements with frames surrounding their edges at least partly or even all around, the goal of the present invention can be met even for plate-like elements without any frames or similar structures. For this reason, a mounting system according to the present invention is characterized by a mounting rail according to any of the preceding paragraphs and characterized further by a first member insert provided in the first insert mounting recess and showing a receiving groove for the plate-like element.
Preferred, this member insert additionally has a wedge-like part filling the gap between the plate-like element and the slanted lower face of the insert mounting recess. This wedge-like part fills the most of or even the whole space between the lower side of the element and the lower face of the recess, which space is opening up towards the outside of the mounting rail, thereby assuring a safe and reliable fixation of the edge of the plate-like element in the groove of the insert and also in the mounting recess.
Preferred, a second member insert is provided in the second insert mounting recess and showing a receiving groove for the plate-like element and a wedge-like part filling the gap between the plate-like element and the second lower face of the second insert mounting recess, with the same advantages as explained above.
To make easier the flowing away of water, molten snow, dirt and the like, the member inserts of a preferred embodiment of the invention are shorter than the mounting rail. Preferred, the member inserts are even shorter than the plate-like elements. For each of all possible embodiments of the member inserts there is a preferred embodiment having essentially constant cross-section over its length, which extends along the mounting rail.
For meeting the goal that separately produced member inserts can be inserted in the recesses of the mounting rail during the mounting process or during production of the mounting system, at least one of the member inserts or the insert mounting recesses have fixing means for fixing at least one of the inserts in the respective insert mounting recesses. Preferably, the fixing means can be disengaged for removal or replacement of the member inserts.
The member inserts can be made of flexible and/or resilient material.
A further advantageous embodiment of the mounting system is characterized by at least the first member insert having a protruding portion extending beyond the lower face of the insert mounting recess and preferably also extending beyond the upper face of the insert mounting recess.
The plane of the roof may also mean any plane parallel to the roof.
The mounting system normally is mounted on a vertical rail, rafter or counter batten, extending vertically on the slanted roof.
According to the invention, the water run off plane is slanted towards the surface of the roof for any of its angles of inclination, as becomes clear from the specification and the drawing figures. The run off plane is declining towards the outside of the mounting rail or the mounting system, respectively, such that the water can run off in a direction towards a vertical plane containing the top or ridge of the roof. This slanted surface allows the water to run off from the insert holding recess of the mounting rail onto the roof. The water can run off more readily because the slope of the plane it runs over can be made large. Previously this angle was limited because mounting the rail under an angle is not optically pleasing. Alternatively the rail could be given a cross-section that is not constant over its length, requiring the rail to be worked over. Moreover, it can no longer be manufactured in a die casting process, what would make the rail expensive.
Also the way the water has to travel to leave the mounting system is much shorter and independent of the location of the module in the mounting system.
In addition to those advantages, the mounting system remains cost-effective, easy to mount, not requiring additional labor to be installed.
The water run off plane may be defined by the surface of water standing still on the lower recess face, ignoring adhesion and cohesion so that the surface of the water extends in a flat plane. According to the invention this plane does not intersect with the module, so that the edge of the module is not in direct contact with any accumulated water. The effective distance from the module edge to the water level depends on the relation between the slope of the roof and the angle of inclination of the lower face of the mounting rail or the water run off plane, and is preferably more than 1 mm. Preferably the minimum distance from this plane to the module or the module holding recess for holding the same is at least 1 mm, preferably more than 5 mm and even more preferred more than 10 mm. Note that this distance also depends on the on the relation between the slope of the roof and the angle of inclination of the lower face of the mounting rail or the water run off plane. The mounting recess extends in the direction of the rail.
Alternatively the water run off plane may be defined as the steepest plane from the lower edge of the module or the module holding recess for holding the same tangentially touching on the upper side of a portion of the lower part of the insert mounting recess, such as the lower recess face or the insert holding means, the plane extending in the direction of the mounting rail or in the direction of the smallest slope of the roof. “Steepest” is meaning “less parallel to the module or the upper recess face”.
The means for holding the plate-like member may be any suitable means for holding for example a solar module. In the simplest case, the means for holding the plate-like member are formed by faces of the module holding recess, preferably the insert mounting recess having a lower and an upper face opposing each other for clamping the module. Moreover, the lower and upper face would be on opposite sides of the module.
Preferably, the water removal plane starts not in the lower module edge or the corresponding portion of its holding means, but at certain, when mounted preferably more or less vertical distance therefrom, so that water is even less likely to come into contact with the module. The minimum distance is larger than 2 mm, preferably more than 5 mm and even more preferred more than 10 mm.
Preferably, the upper face of the insert mounting recess extends mainly parallel to the plate like member when being held. In that way the mounting means are less visible and thus more esthetically pleasing.
Since a solar panel roof normally extends in a plane parallel to the roof it is mounted on, it typically extends under the same slope as the roof. Therefore, the water removal plane may also be defined relative to the modules and thus the upper recess face. The angle δ is equal to angle γ if the water removal plane extends horizontally. Therefore, for δ the same conditions hold as for γ: δ should be larger than the slope α of the roof, preferably at least by an amount β of 1°.
Preferably, the member insert has a mainly constant cross-section. In this way the insert can be made by die casting. After the casting it only needs to be cut to the desired length.
Preferably, the member insert, the insert mounting recess or both have means for fixing the position of the insert in the insert mounting recess so that the insert stays in place, especially when the module is being inserted. In that way installation can be done more easily: The insert is first placed in the insert mounting recess. By making the member insert of a flexible material, the insert not only serves to hold the module, it also protects the module against the rail, which is normally made of a hard material such as a metal like aluminum or a fiber reinforced plastic. Making the insert compressible facilitates the fixing of the insert in the insert mounting recess.
Preferably, the member insert has a protruding portion extending beyond the lower module holding face and preferably also extending beyond the upper face of the insert mounting recess when placed in the insert mounting recess. The insert thus facilitates the mounting of the module by guiding its lower part into the insert and thus the mounting rail.
Further embodiments of the invention are indicated in the figures and in the dependent claims. The list of reference numerals and symbols forms part of the disclosure.
A preferred embodiment of the invention will now be explained in detail with reference to the drawings. In the drawings:
The present invention will be described with reference to exemplary embodiments and the present invention is not limited to a particular embodiment or component parts thereof, except as defined in the appended claims. Embodiments of the present invention may be used with a variety of methods and systems. It will be apparent to one skilled in the art that the present invention may be practiced in a variety of ways within the scope of the claims. Any feature shown in relation to the figures may be applied in general to the invention as described in the claims.
As used herein, the indefinite article (“a”, “an”) denotes the presence of at least one of the referenced item, and the terms multiple and ‘a plurality’ denotes the presence of more than one.
A mounting rail 3′ to be placed essentially horizontally on a slanted roof 2′ is shown, holding a frameless module 6′ with insert 4′. The rail 3′ is made for holding two modules, only the upper one being shown. The mounting rail 3′ has roof mounting means 5′ defining a mounting plane 22′: the plane defining the orientation of the mounting rail 3′ when attached to the roof in normal fashion. The plane 22 being drawn slightly offset for clarity, the plane still extending in parallel to the roof 2′.
A groove or channel 24 is provided for collecting rain water falling on module 6′. As described previously, the water will assemble in this groove and collect dirt and life forms. Moreover, since for esthetical reasons the groove cannot be too slanted to the plane of the roof (=rotated around line of greatest slope of the roof), water will remain in it. During rainfall the groove will completely fill and water and dirt will gather to the level indicated with the dashed line 29 and come in contact with the side of the module that normally is not protected.
Encapsulants, especially EVA, are hydroscopic. Thus water will enter the module causing it to delaminate. As more and more water enters the module, electrical components in the module (cells, interconnectors, diodes, etc.) will be impaired.
Each module 6, 7 may on both its lower and its upper side be held by multiple inserts 4. By using multiple inserts 4 for holding one module, placing them next to each other at an distance in one mounting rail, that module is held more firmly and will bend less, for example under influence of wind or its own weight.
The module insert 4 is held by an insert mounting recess 8 in the mounting rail 3. The module 6 is held by a first module holding recess 10 in that first module insert 4. In this way the module 6 is protected against the mounting rail 3 that is normally made of a hard material such as metal or reinforced plastic. Especially when mounting the module 6, insert 4 protects it so that module 6 is not damaged when it slides into the recess 10 in the rail 3. In the embodiment shown in
By making the insert 4 much shorter than the width of the module (width extending perpendicular to the plane of
Returning to
As water runs off the module 6 it will flow as shown in
Alternatively the water run off plane 23 may be defined as the steepest plane from lower edge of the module 6 or the inserts 4 and tangentially touching on the upper side of a portion of the lower part of the insert mounting recess 8, such as the lower recess face 16 or the insert holding means 12. This the plane 23 is extending in the direction of the mounting rail 3 or in the direction of the smallest slope of the roof 2. “Steepest” is meaning or could be replaced by “at least less parallel to the module or the upper recess face 19”. Ideally the water removal plane 23 starts not in the lower module edge 9 or the corresponding portion of the inserts 4, but at a certain distance, when mounted preferably vertical distance therefrom, so that water is even less likely to come into contact with the module. The minimum distance being larger than 2 mm preferably more than 5 mm and even more preferred more than 10 mm.
As can be seen from
Angle α is formed between the plane of the roof 26 and the horizontal 21 (in a plane perpendicular to a horizontal straight line at the respective location along the mounting rail 3. Normally a is a given in particular by the type and/or construction of the roof (2) and typically lies in the range from 10° to 40°.
The rail 3 may be as short as the width of one module 6, 7. In that case the rail is easy to transport and to bring onto the roof. Connection parts may be inserted from the side into two adjacent rails 3 in order to couple them in longitudinal direction. These connection parts may also have protruding portions protruding between adjacent modules, guaranteeing a distance between them. The connection parts are preferably made of a relatively soft material such polymer. In this way the modules 6, 7 adjacent to each other in horizontal direction will not touch each other what could lead to damage to the modules.
Referring to
Since a solar panel roof normally extends in a plane 15 parallel to the roof 2 it is mounted on, it typically extends with the same slope as the roof. Therefore the water run off plane 23 may also be defined relative to the modules 6, 7 and/or the upper recess face 19. The angle δ is equal to angle γ if plane 23 extends horizontally. Therefore for δ the same conditions hold as for γ: δ should be larger than the slope α of the roof 2, preferably at least by an amount β of 1°.
Even though not shown, it is clear the modules 6, 7 must be supported near their upper edge, too. Preferably this is done by a second similar mounting rail 3 with similar inserts 4, 4b. Near the top or bottom of the slanted roof 2 alternative mounting means may be used.
The invention is not restricted to the embodiments shown. Single or multiple combinations thereof are possible. Features of the shown embodiment may also be applicable to other concepts and embodiments, shown and not shown in the figures, and more particularly to the invention as described in the claims.
| Number | Date | Country | Kind |
|---|---|---|---|
| EP13004752.5 | Oct 2013 | EP | regional |
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/IB2014/002018 | 10/2/2014 | WO | 00 |
