AU2011101200B4

AU2011101200B4 - Rail and mounting system therefor

Info

Publication number: AU2011101200B4
Application number: AU2011101200A
Authority: AU
Inventors: Xuwen HONG; Xiaoming Wang
Original assignee: Kerry J Investments Pty Ltd
Current assignee: Kerry J Investments Pty Ltd
Priority date: 2008-05-16
Filing date: 2011-09-16
Publication date: 2012-08-09
Anticipated expiration: 2017-05-15
Also published as: AU2011101200A4

Abstract

Abstract The invention provides a system which includes at least one entrance which leads to an input cavity and which is profiled to allow for angle insertion of a clamp at any position selected along a length of the entrance.

Description

Regulation 3.2 AUSTRALIA Patents Act 1990 COMPLETE SPECIFICATION INNOVATION PATENT APPLICANT: KERRY J INVESTMENT PTY LTD INVENTION TITLE: RAIL AND MOUNTING SYSTEM THEREFOR The following statement is a full description of this invention, including the best method of performing it known to me: - -2 Rail and Mounting System therefor Field of the Invention This patent relates to a mounting system, for mounting a photovoltaic module. It is particularly used for outdoor mounting installation of photovoltaic modules. 5 Background to the Invention Solar energy is applied in all kinds of fields and plays a wide role in people's daily life, particularly with the development of science and technology as well as the growth of people's environmental consciousness. Solar water heater, solar energy car, solar energy yacht and solar energy bicycle have been 10 coming into more common use gradually, especially solar water heater which has already been used widely. Photovoltaic modules (PV modules) or "solar panels" are the core part of a solar generated electricity system. It undertakes the process of transforming solar radiant energy into electricity, which is then stored in a solar cell or 15 battery or directly used in relevant work. Therefore photovoltaic modules (PV modules) or "solar panels" must be installed outdoors, such as on roofs, where they can receive sufficient radiant energy from the sun. Photovoltaic modules are usually flat and with large surface area in order to obtain more radiant energy. However such a shape and size makes them more affected by wind, 20 so the installation fixture must have strong location capacity and structure strength. USA patent US2006/0156651 discloses a mounting system consisting of aluminum profiles (1, 11) in which threaded sliding blocks (14) inserted in the profiles are used, in particular, for fastening to solar modules and roof 25 supports. The mounting system comprises at least two spaced apart profiled mounting rails (1) respectively with a support (2) limiting the profile height (7) and a connection (3) below the support (2) for the roof mounting. Threaded sliding blocks (14) are inserted in a form-fitting manner in each profiled mounting rail (1) for fastening the connection with the solar modules and the -3 roof mounts. The profiled mounting rail has additional connecting profiles (4, 5, 6), arranged on the side or on the side and bottom, for engagement with complementary connecting profiles (8, 9, 10) of a profiled connecting rail (11). The profiled mounting rail (1) can be extended by sliding shaped pieces (13) 5 with the profile of the profiled mounting rail (1) onto the profiled connecting rail (1 1). However as shown in the Prior Art Figures 1 and 2 in the present document the apparatus of the US document has one kind of photovoltaic modules mounting system, which includes a rail 1 and clamp 2 which in use insert clamp 2 with 10 screw into rail 1, then fix middle clamp 4 with clamp 2 by screw 3, then the photovoltaic modules is fixed between middle clamp 4 and rail 1. The photovoltaic modules are fixed onto rail using doubles of clamp 2, while the other side of rail 1 is fixed onto the roof or other place by clamp 2. With the "L" style clamp 2, its end without screw is designed to be an incurved hook 21, and 15 the baffle 11 on rail 1 is formed accordingly to stop the clamp 2 on lateral orientation. The top end of baffle 11 is formed by a flange, and in cooperation with a hook 21, aims to stop clamp 2 in a longitudinal orientation. However there is substantial movement of the intricate arrangement and interconnection of L-shaped clamp and therefore not a solid and fixed positioning mounting of 20 the photovoltaic modules. Also it can be seen that this structure, in order to retain photovoltaic modules to fixed lateral location, requires the structure to be overcomplicated. Also the photovoltaic modules have large area and perimeter taking substantial fitting space, and the rail 1 needs to be a single length, and so wastes a lot of 25 material and the costs rise correspondingly. Summary of the Invention It is an object of the invention to overcome or at least ameliorate one or more of the problems of the prior art by providing a simple structured mounting system, having excellent lateral and longitudinal location.

-4 In accordance with the invention there is provided a mounting system, for mounting a photovoltaic module, and having: a mounting rack structure including at least one rail and at least two clamps; wherein the at least one rail includes two different entrances forming two input spaces each providing a 5 space to input one of the at least two clamps; with each side of the entrance of the input space being infolded to be a stop bar or the inner wall being shaped to include a stop wall so as to retain one of the at least two clamps within a respective input space by engagement of lateral portions of the one of the at least two clamps to the stop bar and/or the stop wall; and wherein a threaded 10 hole is run through each of the clamps to allow receipt of a bolt to provide fixed mounting of the photovoltaic module to the rack and the rack to a supporting structure. One side of the inner wall of the at least one input space can have a pitch surface narrowing gradually toward the entrance to the inner space so that 15 more than one inner wall under the stop bar or stop wall could be closed fit with the clamp. The two input spaces are mutually perpendicular to form a longitudinal input space and a lateral input space to allow for the substantially perpendicular orientation of the open entrances of the two input spaces to receive two of the 20 at least two clamps in substantially perpendicular arrangement to each other and allow relative mounting of the photovoltaic module to the rack and the rack to a supporting structure. The profile of at least one of the at least two clamps are offset which in one form is similar to a "z" shape having a stop block on each side formed by 25 protruding ends of the "z" shape to engage the stop bars and/or the stop walls so as to retain one of the at least two clamps within the input space. A sliding guide can be provided in one side of the stop block of the at least one clamp and correspondingly there is a sliding guide formed on the input space inner wall of the input space of the rail whereby the clamp is held within the 30 input space and is slidable along the rail to the required fixing point.

-5 Several mating surface grooves are formed on an outer side of the rail allowing for connection to the outer side of a second rail. The mating surface groove on the two rails could be connected together allowing connection of two rails relatively positioned at 180 degrees. 5 The invention also provides a mounting system, for mounting a photovoltaic module, including a mounting rack structure having at least one rail and at least two clamps; wherein the at least one rail includes a substantially H cross sectional structure with a front wall and a back wall and a closed base wall and two different entrances forming two input spaces each providing a space to 10 input one of the at least two clamps; wherein the two input spaces have a top entrance and a lower front entrance through the front wall and are mutually perpendicular to form a longitudinal input space and a lateral input space with perpendicular orientation of the open entrances of the two input spaces to receive clamps in substantially perpendicular arrangement to each other; with 15 one side of the entrance of the input space being infolded to be a stop bar and the inner wall of the other side is shaped to include a stop wall so as to retain one of the at least two clamps within the input space; and wherein a threaded hole is run through each of the clamps to allow receipt of a bolt extend and trap an outer side of a photovoltaic module and be clamped by the bolt and clamp 20 to an upper surface of the linear rail thereby providing fixed mounting of the photovoltaic module to the rack and the rack to a supporting structure There is also provided a mounting rack structure for mounting a photovoltaic module including a substantially H cross sectional structure with a front wall and a back wall and a closed base wall and two different entrances forming 25 two input spaces each providing a space to input one of the at least two clamps and wherein the two input spaces are mutually perpendicular to form a longitudinal input space and a lateral input space to allow for the substantially perpendicular orientation of the open entrances of the two input spaces to receive two of the at least two clamps in substantially perpendicular 30 arrangement to each other and allow relative mounting of the photovoltaic module to the rack and the rack to a supporting structure.

-6 The invention still further provides a method of mounting a photovoltaic module including the steps of: a) Providing at least one elongated linear rail having consistent cross section with two inner spaces extending longitudinally and each inner space 5 having external entrances at angle to each other; b) Providing at least one clamp for insertion in each input space and able to receive a bolt extending through the entrance and be held by the clamp; c) Fixing a bolt to extend and trap an outer side of a photovoltaic module and be clamped by the bolt and clamp to an upper surface of the linear rail 10 d) Fixing a bolt to extend and engage a supporting surface and be clamped by the bolt and clamp the rail to the supporting surface; wherein the rail has a cross sectional shape with the mating surface grooves such that two rails can be connected together end to end by a third rail portion relatively positioned contiguously and at 180 degrees to the other two rails. 15 It can be seen that the invention provides two differences entrance in the rail provided the space to input the clamp. One side of the input space is infolded to be a stop bar. The inner wall of the other side is to be the stop wall. And one side of the inner wall is a pitch surface broadened gradually toward the inner. So, more than one inner wall under the stop bar could be closed fit with the 20 clamp. A threaded hole is run through the clamp. It is designed to be mutual perpendicular for the open orientation of the two input space. The profile of the clamp is offset and in one example is similar with the "z". Two stop block is formed both side. 25 It is formed a sliding guide in the one side of the stop block of the clamp. Correspondingly, there is a sliding guide formed on the input space inner wall of the rail.

-7 One side of above mentioned rail has several mating surface groove, which makes two rails turn 180 degrees relatively, and afterwards the rails could be clamped together. In use, the clamp is placed into the input space of rail, fix press plate and 5 clamped by a screw bolt, so the photovoltaic module is clipped between the press plate and the rail. Fix the photovoltaic module to the rail by the rail and several clamps around the photovoltaic module. And fix it to the roof by another input space, clamp and screw. Both sides of the clamp would be stop by the stop bar and stop block completely to locate the longitudinal orientation 10 after fasten the screw. As the clamp close with the stop block, a close fit is formed between the inner wall of Input space and the clamp to locate the lateral orientation. Therefore, we can get the effect of lateral and longitudinal location by forming two stop blocks on the Input space in the side. It is much simpler than the 15 current technique (American patent US2006/0156651), then save material. Otherwise, clamp of this utility model needn't to be incurved into "L", so clamp of this model has better structure intensity when using material of same volume. In a further form, the invention also provides a mounting system for mounting a 20 photovoltaic module using at least one clamp, the mounting system includes: a mounting rack structure including at least one rail; wherein the at least one rail includes at least one entrance forming an input space providing a cavity in use to input the at least one clamp; the at least one entrance being shaped to form a stop bar on one side of 25 the entrance and a stop wall on the other side of the entrance so as to retain in use the at least one clamp within the input space by engagement of lateral portions of the at least one clamp respectively with the stop bar and with the stop wall; wherein the stop bar and the stop wall are offset relative to each other 30 thereby allowing the at least one clamp to be inserted into the input space so -8 that engagement of a bolt with a threaded hole which extends through the clamp allows for fixed mounting of the photovoltaic module to the rack. In another form, the invention also provides a mounting system for mounting a photovoltaic module, the mounting system includes: 5 a mounting rack structure including at least one rail and at least one clamp; wherein the at least one rail includes at least one entrance forming an input space providing a cavity in use to input the at least one clamp; the at least one entrance being shaped to form a stop bar on one side of 10 the entrance and a stop wall on the other side of the entrance which is offset relative to the stop bar so as to retain the at least one clamp in use within the input space by engagement of lateral portions of the at least one clamp respectively with the stop bar and with the stop wall; wherein the clamp has a threaded hole which extends through the 15 clamp thereby to allow receipt of a bolt allows for fixed mounting of the photovoltaic module to the rack and the rack to a supporting structure; and wherein one side of the inner wall of the input space has a pitched surface narrowing gradually toward the entrance of the input space thereby gradually reducing a cross sectional diameter of the input space towards the 20 entrance. In an additional form, the invention provides a rail for use with a mounting system to mount a photovoltaic module, the mounting system; the rail includes two different entrances forming two input spaces each providing a space in use to input at least one clamp, 25 one side of an entrance of each input space being infolded to form a stop bar and an opposite side of the entrance being shaped to form a stop wall; the at least one clamp includes a shaped body thereby to define a protruding end at each side of the shaped body so that a stop block is formed 30 at each protruding end of the shaped body; -9 wherein the stop bar and the stop wall of each entrance of the two input spaces are offset relative to each other; wherein the stop blocks of the shape body are offset relative to each other thereby to allow the protruding ends of the shaped body to substantially 5 match the offset of the stop bar and the stop wall; wherein the offset nature of the stop blocks and the stop bar and stop wall allow the at least one clamp to be inserted at a first angle into a selected input space while securing the clamp to the selected input space by engagement of the stop blocks with a respective underside of the stop bar and 10 stop wall when the clamp is pulled from the selected input space in a second angle which is different from the first and which extends substantially perpendicular relative to the entrance of the selected input space; and wherein the offset nature of the stop bar and the stop wall allows the at least one clamp to be inserted into the input space at any position 15 selected along a length of the rail. In a further form, the invention also extends to a rail for use with a mounting system to mount a photovoltaic module, the mounting system; the rail includes at least one entrance forming an input space providing a space in use to input at least one clamp, 20 one side of an entrance of the input space being infolded to form a stop bar and an opposite side of the entrance being shaped to form a stop wall; .the at least one clamp includes a shaped body thereby to define a protruding end at each side of the shaped body so that a stop block is 25 formed at each protruding end of the shaped body; wherein the stop bar and the stop wall of the entrance of the input space are offset relative to each other; wherein the stop blocks of the shape body are offset relative to each other thereby to allow the protruding ends of the shaped body to 30 substantially match the offset of the stop bar and the stop wall; wherein the offset nature of the stop blocks and the stop bar and stop wall allow the at least one clamp to be inserted at a first angle into -10 the input space while securing the clamp to the input space by engagement of the stop blocks with a respective underside of the stop bar and stop wall when the clamp is pulled from the input space in a second angle which is different from the first and which extends 5 substantially perpendicular relative to the entrance of the input space; and wherein the offset nature of the stop bar and the stop wall allows the at least one clamp to be inserted into the input space at any position selected along a length of the rail. Brief Description of the Drawings 10 In order that the invention is more readily understood an embodiment will be described by way of illustration only with reference to the drawings wherein: Figure 1 is a diagrammatic view of a section of rail in prior art; Figure 2 is a diagrammatic view of a working state sketch of a rail structure in prior art; 15 Figure 3 is a diagrammatic sectional view a photovoltaic module mounting system in accordance with an embodiment of the invention; Figure 4 is a diagrammatic view of rail structure of the photovoltaic module mounting system of Figure 3; Figure 5 is a diagrammatic sectional view of the clamp of the photovoltaic 20 module mounting system of Figure 3; Figure 6 is a diagrammatic side view of the of the photovoltaic module mounting system of Figure 3; Figure 7 is a diagrammatic sectional view of a combination of two rails joined by the out flange in a photovoltaic module mounting system of Figure 3; 25 and - 11 Figure 8 is a diagrammatic perspective view of the connection between the rails by the out flange of the combination of two rails of Figure 7. Description of Illustrated Embodiment of the Invention An embodiment of the invention is shown in Figures 3 to 8. Figures 3 and 4 5 are an example of photovoltaic modules mounting system using this invention and includes a mounting rack structure a rail 5 and two clamps 6 for holding a photovoltaic module 7 by a bolt 3 extending from a press plate 4 on an outer side of the module 7 to one of the clamps 6 mounted in an upper input space 51A in the rail 5. 10 The rail 5 is continuous elongated rail with primarily a substantially consistent H cross sectional structure with a front wall 11, a back wall 12 and a closed base wall 13 with a cross member 14 extending substantially across a middle section between the front wall towards the back wall to define two input spaces 51A and 51B. Entrances 50A and 50B are provided relatively for each of the 15 two input spaces 51A and 51B each providing a space to input one of the at least two clamps 6. As shown in Figure 4, the Rail 5 has two input spaces 51A and 51B with different orientations, which are mutual perpendicular. The longitudinal input space 51A in the upper section of the substantially H shape rail with the upper 20 entrance 50A is used to hold the clamp 6 to fix the photovoltaic module 7. The lateral input space 51 B with the lateral lower front entrance 50B is used to hold the clamp 6 to fix the rail 5 to the pre-location of the supporting structure. Each side of the entrance 50A or 50B of the input spaces 51A and 51B are either infolded to be a stop bar or the inner wall being shaped to include a stop 25 wall so as to retain one of the at least two clamps within a respective input space by engagement of lateral portions of the one of the at least two clamps to the stop bar and/or the stop wall. In particular the longitudinal input space 51A has one side of the input space hatch forming a stop bar 52, the other side forming a stop block 53 on the inner wall 54. The stop block 53 of the - 12 longitudinal input space, the top of the inner wall 54 towards the entrance but below the stop block 53 and the clamp 6 form a close fit. However the inner wall 54 is an inclined plane which gradually widens toward the entrance 50A. As shown in Figure 5 a threaded hole is run through each of the clamps 6 to 5 allow receipt of a bolt 3 to provide fixed mounting of the photovoltaic module 7 to the rack 5 and the rack to a supporting structure. In particular the clamp 6 has an offset nature in the form of a'Z' profile. It is formed having a stop block 62 on each side formed by protruding ends of the "z" shape. There is a threaded hole 61 throughout the clamp 6 body. 10 As shown in cross section in Figure 3 and in a diagrammatic side view in Figure 6 when using this invention, the clamp 6 is located in the rail longitudinal input space 51A, and a spaced press plate 4 is fixed to the clamp 6 by a bolt 6. The photovoltaic module 7 would be clipped between the press plate 4 and the rail 5. It can take several clamps 6 along the rail to fix the surround of the 15 photovoltaic module to the rail 5. The fastening of the photovoltaic module 7 on the roof or the other places is dependent on the lateral input space 51 B in the rail 5, and the clamp 6 and the bolt 3 to fix the rail 5 to the roof or the other places. When fastening the bolt 3, the two end stop blocks 62 of the z-shaped clamp 6 20 would close against the stop bar 52 and stop wall 53, to form a fixed longitudinal location. When the clamp 6 is closed to the stop wall 53, the inner wall of the input space 51 would be close fitting with clamp 6 in a lateral location. Since the inner wall 54 is an inclined plane which widens gradually toward the entrance, it is easier to insert the clamp 6 into the input space 51 at 25 the wide position. When fixing the rail 5, due to the weight of the photovoltaic module 7 and the rail 5, it is impossible to shake in the longitudinal orientation as the location is secured. It can be seen that the close fit structure between the inner wall 54 of - 13 the lateral input space 51 and the clamp 6 do not need to have an inner wall 54 with an inclined plane. For the lateral location of the clamp 6 in the rail 5, there is formed a location slide rail 56 on the inner wall 54 of the base wall 13 in the lateral input space 5 51 B of the rail 5. A sliding guide 63 is formed in one side stop block of the clamp 6. The lateral location performance is strengthened by the fit between the slide rail 56 and the sliding guide 63. In addition, with reference to Figure 7, there are shown two rail portions that can be interfitted. Each rail has an outer side of the back wall 12 of the rail 5 10 formed with pair of inwardly extending flanges 55A on a top section and pair of inwardly extending flanges 55B on a bottom section, which can be used to engage each other after two rails are position back wall to back wall but with a relative rotation of 180 degrees. This can particularly be use to have a short section connect two end to end long sections to form a continuous rail and 15 increase the length of the rail 5 as shown in Figure 8. At best can be seen in Figure 3, the stop bar and the stop wall are offset relative to each other thereby allowing the at least one clamp to be inserted into the input space so that engagement of a bolt with a threaded hole which extends through the clamp allows for fixed mounting of the photovoltaic module 20 to the rack. Thus, the offset nature of the stop blocks and the stop bar and stop wall allow the clamp to be inserted into the input space through the stepped profile of the entrance using a first angle while securing the clamp to the input space by engagement of the stop blocks with a respective underside of the stop bar and stop wall when the clamp is pulled from the input space in a 25 second angle which is different from the first and which extends substantially perpendicular relative to the entrance of the input space. Generally, it can be seen that the invention provides a secure mechanism for the lateral and the longitudinal location of a photovoltaic module, and it is simpler, compact, effective, adaptive and saves material than the prior art..

- 14 Any reference to publications in this specification is not an admission that the disclosures constitute common general knowledge in Australia.

Claims

1. A mounting system for mounting a photovoltaic module using at least one clamp, the mounting system includes: a mounting rack structure including at least one rail; 5 wherein the at least one rail includes at least one entrance forming an input space providing a cavity in use to input the at least one clamp; the at least one entrance being shaped to form a stop bar on one side of the entrance and a stop wall on the other side of the entrance 10 so as to retain in use the at least one clamp within the input space by engagement of lateral portions of the at least one clamp respectively with the stop bar and with the stop wall; wherein the stop bar and the stop wall are offset relative to each other thereby allowing the at least one clamp to be inserted into the 15 input space so that engagement of a bolt with a threaded hole which extends through the clamp allows for fixed mounting of the photovoltaic module to the rack.

2. A mounting system for mounting a photovoltaic module, the mounting 20 system includes: a mounting rack structure including at least one rail and at least one clamp; wherein the at least one rail includes at least one entrance forming an input space providing a cavity in use to input the at least one clamp; 25 the at least one entrance being shaped to form a stop bar on one side of the entrance and a stop wall on the other side of the entrance which is offset relative to the stop bar so as to retain the at least one clamp in use within the input space by engagement of lateral portions of the at least one clamp respectively with the stop bar and with the 30 stop wall; wherein the clamp has a threaded hole which extends through the clamp thereby to allow receipt of a bolt allows for fixed mounting of the - 16 photovoltaic module to the rack and the rack to a supporting structure; and wherein one side of the inner wall of the input space has a pitched surface narrowing gradually toward the entrance of the input space 5 thereby gradually reducing a cross sectional diameter of the input space towards the entrance.

3. A mounting system for mounting a photovoltaic module using at least one clamp according to claim 1 or 2; wherein the at least one clamp 10 includes a shaped body thereby to define a protruding end at each side of the shaped body so that a stop block is formed at each protruding end of the shaped body; wherein the stop bar and the stop wall of the entrance of the input space is offset relative to each other thereby to provide the entrance 15 with a stepped profile; wherein the stop blocks of the shape body are offset relative to each other thereby to allow the protruding ends of the shaped body to substantially match the offset of the stop bar and the stop wall; and wherein the offset nature of the stop blocks and the stop bar 20 and stop wall allow the clamp to be inserted into the input space through the stepped profile of the entrance using a first angle while securing the clamp to the input space by engagement of the stop blocks with a respective underside of the stop bar and stop wall when the clamp is pulled from the input space in a second angle which is different from the 25 first and which extends substantially perpendicular relative to the entrance of the input space.

4. A rail for use with a mounting system to mount a photovoltaic module, the mounting system; 30 the rail includes at least one entrance forming an input space providing a space in use to input at least one clamp, - 17 one side of an entrance of the input space being infolded to form a stop bar and an opposite side of the entrance being shaped to form a stop wall; the at least one clamp includes a shaped body thereby to define 5 a protruding end at each side of the shaped body so that a stop block is formed at each protruding end of the shaped body; wherein the stop bar and the stop wall of the entrance of the input space are offset relative to each other; wherein the stop blocks of the shape body are offset relative to 10 each other thereby to allow the protruding ends of the shaped body to substantially match the offset of the stop bar and the stop wall; wherein the offset nature of the stop blocks and the stop bar and stop wall allow the at least one clamp to be inserted at a first angle into the input space while securing the clamp to the input space by 15 engagement of the stop blocks with a respective underside of the stop bar and stop wall when the clamp is pulled from the input space in a second angle which is different from the first and which extends substantially perpendicular relative to the entrance of the input space; and wherein the offset nature of the stop bar and the stop wall 20 allows the at least one clamp to be inserted into the input space at any position selected along a length of the rail.

5. A rail for use with a mounting system to mount a photovoltaic module as substantially as hereinbefore described with reference to above 25 description and Figures 3 to 8.