WO2023248254A1

WO2023248254A1 - U cleat based long rail structure for mounting solar module system

Info

Publication number: WO2023248254A1
Application number: PCT/IN2023/050610
Authority: WO
Inventors: Mohammad AZIM IQBAL
Original assignee: Sunrack Technologies Llp
Priority date: 2022-06-25
Filing date: 2023-06-23
Publication date: 2023-12-28

Abstract

The present invention provides a Rooftop Solar Module mounting system with set of U Cleat. Solar Module is clamped to the Rail which is supported by set of U cleats which is in turn anchored to Roof. Each set of U Cleat comprises of 2 components namely, External U Cleat and Internal U Cleat. Rail on which module is clamped is snapped into the Internal U cleat and External U cleat is slid over internal U Cleat. Two such assemblies containing External U Cleat, Internal U Cleat, fasteners, Module mounting rail and Rail Nuts are installed. Module is installed on top of two sets mentioned above and Clamped to the Rail using Module Clamps and Rail Nuts. The Anchoring fasteners for External U Cleat can be any type of Anchor Bolts, Self-Drilling and self-tapping screws, Rivets and combination these depending on type of roof.

Description

U CLEAT BASED LONG RAIL STRUCTURE FOR MOUNTING SOLAR MODULE SYSTEM

CROSS - REFERENCE TO RELATED PATENT APPLICATION

The embodiments herein claim the priority of Indian patent application 202221036589 filed on June 25, 2022.

Field of Invention

The present invention relates to the field solar modules, in particular relates to U cleat based long rail structure for mounting solar modules which enables easy installation of the solar module system.

Background of the Invention

Solar PV Electricity Power generation uses Solar Modules which are mounted on Structures made of variety of materials and structures. Solar PV modules come in different sizes and can be installed on Roof of the buildings and at ground levels. Many such solar modules are mounted on uneven and titled structures which prove to be a challenge in balancing various loads of solar systems mounted on it. One such Rooftop Solar module mounting solution is by using Special Aluminium Long Rails on which Solar Modules are installed. This type of system is called Long Rail /Full Rail solar module mounting structure.

Generally, the Rails mounted on supports give clearance from Roof to solar modules. This clearance is required for efficient operation of Solar modules and for maintenance. Traditionally the shape of the support used is an L cleat. These L cleats are anchored to roof by different means depending on Type of Roof. These L Cleats are spaced such that the maximum load bearing span of Rail as per load combinations (Dead load, Wind load, live load, etc) are applicable as per relevant Codes and standards. Also, the span is dependent on Roof strength and distance between load bearing members of Building, like Shed Purlins in case of industrial sheds. The main drawback of this kind of system is with L cleat used in the mounting structure. During installation, with weight of modules, the L cleat tends to tilt to one side, which is undesirable and will hinder uniform module installation. Modules installed on such rails look wavy. Complete wight is concentrated on one side of L cleat and rail, putting extreme stress at single point of contact. This is also the reason for L cleat bending onto one side.

Various structures and custom fixtures have been proposed in the art for mounting solar panels and assemblies and to further provide stability to the solar systems.

US Patent application US8615939B2 discloses a photovoltaic module mounting system using clamps to attach the modules to a mounting structure, thereby providing a universal mounting structure for use with laminate or framed modules of differing shapes and sizes, from different manufacturers.

Another Patent application WO2013119555A2 discloses a photovoltaic module mounting assemblies with mounting clamps for connecting multiple photovoltaic modules into a photovoltaic array. One embodiment of the mounting assembly includes mounting clamps that are positioned on the mounting assembly parallel to the scribe lines of the module. Another embodiment of the mounting assembly uses mounting clamps that are configured to hold a portion of the module at a predetermined distance away from the photovoltaic cells of the module.

Although all of the prior-arts are effective in their intended purposes, the existing systems do not provide an efficient, easy and solid structures that can evenly carry the weight of the mounted solar modules and that further do not tilt during installation. The prior arts further do not provide stability to the structures carrying the weight of the solar module systems. Therefore there exists a need in the art for solar module mounting structure that enables uniform module installation. And also there exists a need for a simple yet robust mounting arrangement for long rails which eliminates the above-mentioned drawbacks and give maximum stability to overall system. The present invention provides U cleat based long rail structure for mounting solar module system

Wherein the rails sit exactly in the middle of a U cleat and using through bolt that runs across the cross-section of both Outer U cleat and inner U cleat, the weight of the system is uniformly distributed to either side of Cleats.

Objects of the Invention:

The main object of the present invention is to provide a solar module mounting system with a set of U Cleats.

The primary object of the present invention to provide an efficient and uniform installation of a solar module system.

Another object of the present invention is to eliminate the tilting movement of complete mounting assembly when mounted on the structure.

Another object of the present invention is to provide 100% contact surface between External U Cleat (13) and mounting surface thus eliminating the risk of water ingress when installed on industrial metal roofing sheets.

Summary of the Invention

The present invention provides a solar module system with a set of U cleats (external and internal U cleats). A Minimum of four U cleat sets are required for installing one solar module. The U Cleats are installed on Roof as per the designer requirement, based on roof strength and rail span required, using any standard fasteners or anchors available. Then inner U cleat is slid into the outer U cleat. Position of inner U can be varied for increasing the clearance from solar module to roof. The Long Rail is snapped into the Internal U Cleat and this assembly is held together using a bolt through both the U cleat. Both Inner U cleat and Long Rail are provided with inter-locking teeth to hold each other together. Each Rail is supported by minimum 2 sets of U cleats and two such Rail assemblies are required to hold one solar module. The solar modules are then clamped to rail using regular industry standard Solar module mounting clamps.

As rails sit exactly in the middle of U cleat and using through bolt that runs across the cross-section of both Outer U cleat and inner U cleat, the weight is distributed uniformly to either side of Cleats. As Rail is installed within the Outer U cleat, the load acts perpendicularly on the centre of the Clamp, thus eliminating the Tilting or Cleats and Rails.

Other features and advantages of embodiments will be apparent from the accompanying drawings and from the detailed description that follows.

Brief Description of the Drawings

FIG. 1 is a perspective illustration of Long Rail Mounting using U Cleat in accordance with the present invention.

FIG. 2 is the side view of Solar Module mounting structure shown in figure 1.

FIG. 3 is the front View of Solar panel module mounting structure shown in figure 1.

FIG. 4 is a perspective drawing of a Solar module installation in accordance with the present invention.

FIG. 5 is a perspective drawing of a typical multi-panel installation in accordance with the present invention.

FIG. 6 is a close-up perspective view of a U cleat support which holds the Rail on which solar module is mounted in accordance with the present invention.

FIG. 6A is an expanded view of the exploded view of U cleat support shown in FIG. 6 in accordance with the present invention.

FIG. 7 is a close-up perspective view of an External U cleat support for securing Internal U cleat in accordance with the present invention.

FIG. 8 is a close-up perspective view of an Internal U cleat for holding the Long Rail in accordance with the present invention.

FIG. 9 is a perspective drawing of anchoring methods of the External U cleat in accordance with the present invention. While the invention is amenable to various modifications and alternative forms, specifics thereof have been shown by way of example in the drawings and will be described in detail. It should be understood, however, that the intention is not to limit the invention to the particular embodiments described. On the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the scope of the invention.

Hereinafter, preferred embodiments of the present invention will be described in detail with reference to the accompanying drawings. Prior to this, terms and words used in the present specification and claims should not be construed as limited to ordinary or dictionary terms, and the inventor should appropriately interpret the concept of the term appropriately to describe its own invention in the best way. The present invention should be construed as meaning and concept consistent with the technical idea of the present invention based on the principle that it can be defined. Therefore, the embodiments described in this specification and the configurations shown in the drawings are only the most preferred embodiments of the present invention and do not represent all the technical ideas of the present invention. Therefore, it should be understood that equivalents and modifications are possible.

Detailed Description of the Invention with Respect to the Drawings

The present invention as embodied by "U cleat based long rail structure for mounting solar module system" succinctly fulfils the above-mentioned need(s) in the art. The present invention has objective(s) arising as a result of the above-mentioned need(s), said objective(s) being enumerated below. In as much as the objective(s) of the present invention are enumerated, it will be obvious to a person skilled in the art that, the enumerated objective(s) are not exhaustive of the present invention in its entirety, and are enclosed solely for the purpose of illustration. Further, the present invention encloses within its scope and purview, any structural alternative(s) and/or any functional equivalent(s) even though, such structural alternative(s) and/or any functional equivalent(s) are not mentioned explicitly herein or elsewhere, in the present disclosure. The present invention therefore encompasses also, any improvisation(s)/ modification/ s) applied to the structural alternative(s)/functional alternative(s) within its scope and purview. The present invention may be embodied in other specific form(s) without departing from the spirit or essential attributes thereof. Throughout this specification, the use of the word "comprise" and variations such as "comprises" and "comprising" may imply the inclusion of an element or elements not specifically recited.

The words or nomenclature can be interchanged with other words conveying the same meaning or functionality. For Example, Internal can be interchanged with Inner or inside.

The present invention discloses a U cleat based long rail structure for mounting solar module system. As seen in figs 1 to 4 the present invention discloses a complete solar Module mounting system (11) comprising a Long Rail (12), a set of External U Cleats (13), a set of Internal U Cleats (14), a M8x60mm hex head full thread bolt (15), plain washers (16), spring washer (17), and M8 Hex nut (18) and plurality of anchor fasteners (19).

In the preferred embodiment of the present invention, the Solar module (20) is placed on top of Long Rail (12) and clamped to Rail. The clamping is done according to general industrial practice by using Rail nut (21) and either end clamp (22) or mid Clamp (23). The External U (13) cleat has a hole at the bottom for anchoring the cleat to mounting surface which can be accomplished either by using Self Drilling screw (19) or Blind Rivet (25) or Anchor fasteners (O). Once External U Cleat (13) is anchored to base surface, the internal U Cleat (14) is slid into the External U Cleat (13).

In the preferred embodiment of the present invention, both U Cleats (13, 14) are provided with teeth (26) for easy interlocking with each other. Height of Internal U cleat (14) within External U cleat (13) can be adjusted as per solar module manufacturer guidelines for installing module and operation and Maintenance requirement. Once desired height is set, a M8 bolt (15) is installed through both the U Cleats and loosely locked using Hex Nut (18) and Washers (F, G). This procedure is repeated for all U Cleat assemblies.

In the preferred embodiment of the present invention, the long rail (12) is pushed into the Internal U Cleat (14) from top for all U cleat assemblies. An interlocking ridge (27) on Long Rail (12) and Triangular projections (28) on inner walls of Internal U Cleat (14) are provided such that once snapped, the Long Rail (12) cannot be pulled out the same way from top. Once the long rail (12) is inside the Internal U Cleat (14), the M8 Hex nut (18) is tightened to at least 10 N-m of torque. Because of this tightening the U-Shaped Notch (29) of Internal U cleat (14) is compressed to tightly hold the Long Rail (12) within the Internal U Cleat (14), thus eliminating the need for drilling the long rail (12) and therefore not compromising its (12) strength.

In the preferred embodiment of the present invention, with use of U Cleats (13, 14) instead of traditionally used L Cleat, the load acts perpendicularly on the centre of the Cleat (13), thus eliminating the tilting movement of complete mounting assembly 11. As tilt is eliminated, the Long Rails (12) are flat, and Solar module (20) sits on long rail (12) with 100% contact with the surface. As External U Cleat (13) takes load on both the flanges, the weight is equally distributed thus reducing the wobbling effect. Because of which, 100% contact surface between External U Cleat (13) and mounting surface is achieved eliminating the risk of water ingress when installed on industrial metal roofing sheets (30). Strength to weight ratio has increased in this type of U cleat mounting solution 11 compared to traditional L Cleat design, which means weight is reduced but strength is increased with U Cleat design 11 compared to traditional L Cleat design.

In another embodiment of the present invention, the Fig. 5 and Fig. 6 illustrates the Industry standard procedure to install multiple solar modules (20) in a stack on long rails (12). Continuous Long rails (12) are installed one after the other for longer spans. At the edge of last module (20), End clamps (22) are used and in between two panels, Mid clamps (23) that hold two adjacent modules (20) simultaneously. Rail nuts (21) are used along with clamps (22, 23) to sandwich the module tightly between Rail and Clamp.

Fig. 6 and 6A shows the respective assembled and exploded view of assembly of External U Cleat (13), Internal U cleat (14), Fasteners (15, 16, 17, H, 18), Long Rail (12) and Rail nut (21).

Fig. 7 illustrates the External U Cleat (13). This component/ part is made of 6000 series structural aluminium alloy which is tempered to T5 or T6 hardness as per user requirement. Teeth (26) are given to inner walls. This provides good interlocking ability and better friction due to increased surface area to hold the Internal U Cleat. At the centre of bottom surface (31) of External U Cleat thickness is increased to provide enough volume to avoid tearing of Cleat. A vertical M8x20mm slot (32) hole is given on both sides walls of Cleat to provide height adjustability for Internal U Cleat (14) installation. This complete External U cleat (13) with all above features discussed above is made as unibody extruded Aluminium Alloy.

Fig. 8 illustrates the Internal U Cleat (14). This component/ part is made of 6000 series structural aluminium alloy which is tempered to T5 or T6 hardness as per user requirement. Teeth are given to outer walls. This provides good interlocking ability and better friction due to increased surface area to clamp with External U Cleat (13). M8 hole is given at the lower end for locking the Internal U Cleat (14) to External U Cleat (13) using M8 threaded bolt (15). On either side of inner walls ledge projection (33) is given to support the Long Rail (12) inside the U Cleat (14) after snapping it into place. Snapping action is achieved by triangular seam projections (28) on walls of U cleat (14). The slope/hypotenuse section of triangular section (28) eases the Long Rail (12) snapping when it is pushed from top. Once inside the horizontal base of triangular projection restricts the uplift, thus locking the Long Rail (12) between Ledge Projection (33) and Triangular Projection (28). At the centre of bottom surface of Cleat small U-shaped notch (29) is given. This notch (29) gets compressed when M8 bolt (15) is tightened once External U cleat (13), Internal U Cleat (14) and Long Rail (12) are assembled.

As seen in fig 9, depending on joint strength calculated using regular Industry standard for design, wind speed and site installation conditions, type of anchoring method is defined, and accordingly correct size hole is made at the bottom of the U Cleat (13).

EXAMPLE

The present invention provides a complete solar Module mounting system (11) comprising a Long Rail (12), an External U Cleat (13), an Internal U Cleat (14), a M8x60mm hex head full thread bolt (15), plain washers (16), spring washer (17), and M8 Hex nut (18) and plurality of anchor fasteners (19). The Solar module (20) is placed on top of Long Rail (12) and Clamped to Rail. The clamping is done according to general industrial practice by using Rail nut (21) and either end clamp (22) or mid Clamp (23). The External U (13) cleat has a hole at the bottom for anchoring the cleat to mounting surface which can be accomplished either by using Self Drilling screw (19) or Blind Rivet (25) or Anchor fasteners (24). Once External U Cleat (13) is anchored to base surface, the internal U Cleat (14) is slid into the External U Cleat (13).

Both U Cleats are provided with teeth (26) for easy interlocking with each other. Height of Internal U cleat (14) within External U cleat (13) can be adjusted. Once desired height is set, a M8 bolt (15) is installed through both the U Cleats and loosely locked using Hex Nut (18) and Washers (F, G). The long rail (12) is pushed into the Internal U Cleat (14) from top for all U cleat assemblies. An interlocking ridge (27) on Long Rail (12) and Triangular projections (28) on inner walls of Internal U Cleat (14) are provided such the once snapped the Long Rail (12) cannot pulled out the same way from top. Once Long Rail (12) is inside the Internal U Cleat (14), the M8 Hex nut (18) is tightened. Because of this tightening the U-Shaped Notch (29) of Internal U cleat (14) is compressed to tightly hold the Long Rail (12) within the Internal U Cleat (14), thus eliminating the need for drilling the long rail (12) and therefore not compromising its (12) strength. With use of U Cleats (13, 14) the long Rails (12) are flat, and Solar module (20) sits on long rail (12) with 100% contact surface.

Advantages of the present invention:

• Double U Cleat design is unique for use in Solar Module Mounting system using Long Rail.

• U Cleat Height upto 150mm. Height of External U Cleat can be extended up to 150mm without any stability issues unlike in L Cleat were increasing the height inversely effects the stability as centre of gravity is offset from actual volumetric centre. As stability decreases, the issues mentioned in above points increases.

• Increased thickness at the bottom of U cleat can be provided to give maximum volume for strong anchoring.

• Interlocking teeth given on walls of both Internal and External U Cleats gives maximum frictional strength because of more surface area. • Snap fitting of Long Rail inside the Internal U Cleat reduces the system installation time, unlike traditionally used L cleat design, where a dedicated person needs to hold the rail until it is fully tightened. The ridge made on the Long Rail to mate and snap into the Internal U Cleat is unique.

• Reduced shear force on bolt in U cleat design when compared to L cleat design. In traditional L Cleat design, M8 bolt takes complete shear load at one point because the rail is supported only on one side. But in U cleat design the bolt is supported at both the ends distributing the shear load on bolt to two points. This reduces the chance of bolt damage to half.

• For longer spans of Long Rails between the supports, the Internal U Cleat length can be increased to support the extra span.

• Inside the Internal L Cleat, a small U-shaped notch is provided. This notch gets compressed once whole support assembly is tightened. If we do not give this notch while tightening the base will deform or break which reduced the structural strength of Cleat. Providing notch facilitates compression without breaking or compromising the structural strength.

It will be apparent to a person skilled in the art that the above description is for illustrative purposes only and should not be considered as limiting. Various modifications, additions, alterations, and improvements without deviating from the scope of the invention may be made by a person skilled in the art.

Claims

We claim,

1. A solar module mounting system, comprising of: a Long Rail (12) provided with an interlocking ridge (27); a plurality of external U cleat (13) provided with a hole at the bottom for anchoring the cleat to a mounting surface; a plurality of Internal U Cleat (14) provided with triangular projections (28) on inner walls and a u-shaped notch (29), wherein the ridge (27) on the long rail (12) is made to mate with triangular projections (28) and snap into the Internal U Cleat (14),

Wherein a solar module (20) is placed on top of long rail (12) and clamped to the rail (12).

2. The system as claimed in claim 1, wherein both external and internal U Cleats (13, 14) are provided with teeth (26) for easy interlocking with each other which enables height adjustment of Internal U cleat (14) within External U cleat (13).

3. The system as claimed in claim 2, wherein after the height of the Internal U cleat (14) within External U cleat (13) is set, a M8 bolt (15) is installed through both the U Cleats (13, 14) and loosely locked using Hex Nut (18) and Washers (16, 17).

4. The system as claimed in claim 1, wherein the long rail (12) is pushed into the Internal U Cleat (14) from top for the U cleat assembly, wherein the interlocking ridge (27) on Long Rail (12) and Triangular projections (28) on inner walls of Internal U Cleat (14) are provided such that the once they are snapped together, the Long Rail (12) cannot be pulled out the same way from top.

5. The system as claimed in claim 1, wherein on either side of inner walls of the internal U Cleat (14), ledge projection (33) is given to support the Long Rail (12) inside the U Cleat (14) after snapping it into place.

6. The system as claimed in claim 1, wherein the U Cleats (13, 14) enables the load mounted on the system to act perpendicularly on the centre of the Cleat (13), thus eliminating the tilting movement of complete mounting assembly (11), thus enabling the solar module (20) to be positioned on long rail (12) with 100% contact with the surface.

7. The system as claimed in claim 1, wherein the U-shaped notch (29) provided at the center of bottom surface of internal U Cleat (14) gets compressed when M8 bolt (15) is tightened when the external U cleat (13), the internal U Cleat (14) and long Rail (12) are assembled.

8. The system as claimed in claim 1, wherein continuous Long rails (12) are installed one after the other and at the edge of last solar module (20), a set of end clamps (22) are used and in between two solar panel modules, mid clamps (23) are provided to hold two adjacent modules (20) simultaneously, wherein rail nuts (21) are used along with clamps (22, 23) to sandwich the module tightly between Rail (12) and Clamps.

9. The system as claimed in claim 1, wherein the cleats (13, 14) are made of structural aluminium alloy tempered to T5 or T6 hardness.