DE202004021286U1 - Corner bracket for use when stacking photovoltaic modules has central shelf which supports corner of module, studs on top of bracket fitting into recesses in base of bracket above to hold stack together - Google Patents

Abstract

The corner bracket for use when stacking photovoltaic modules has a central shelf (2) which supports the corner of the module. Studs (6) on top of the bracket fit into recesses (8) in the base of the bracket above to hold the stack together. Alternatively a tongue-and-groove system is sued to connect the brackets.

Description

The The invention relates to a modular plug-in system for safe storage of horizontally stacked photovoltaic modules during transport.

thanks a transformed energy consciousness of the population and supported by state funding initiatives The use of renewable energy sources has become more and more economical Importance gained - this especially applies to the field of photovoltaics, the conversion of sunlight into electricity. In many places - not only in Germany - are powerful, state-of-the-art equipped factories emerged, in which today photovoltaic modules after most rational methods are mass-produced to to be shipped to all parts of Europe and the world.

considerations innovative rationalization must not only be based on production criteria restrict, but have to also the area of shipping or packaging and transport security to capture.

• – einer vorderseitigen – meist 4 mm dicken – Einscheiben-Sicherheitsglasscheibe,
• – zwei verschmolzenen Lagen transparenter Laminierfolie, zwischen welche die Photovoltaik-Zellen – meist aus Silicium – sowie ein elektrisches Leitersystem eingebettet sind
• – sowie einer die Rückseite dampfdiffusionsdicht verschließenden speziellen Kunststoff-Folie. Man spricht in diesem Fall von Glas/Kunststoff-Modulen. Die Rückseite kann statt dessen aber auch mit einer Glasscheibe versehen sein (Glas/Glas-Module).

Photovoltaic modules (PV modules) are made in the standard version:

• A front-side - usually 4 mm thick - toughened safety glass pane,
• - Two fused layers of transparent laminating between which the photovoltaic cells - usually made of silicon - and an electrical conductor system are embedded
• - As well as a vapor-tight sealing the rear special plastic film. One speaks in this case of glass / plastic modules. Instead, the rear side can also be provided with a glass pane (glass / glass modules).

In most cases are standard PV modules with a frame made of drawn aluminum profile equipped, for example, with a frame depth of 42 mm.

In rarer cases but also frameless PV modules - both in the execution as glass / plastic modules as well as glass / glass modules - shipped.

The Size of standard PV modules usually lies in the range between 0.8 and 1.6 square meters. The weight is with framed modules usually in the range between 14 and 28 kg. Glass-glass modules are about 60% heavier.

For the transport The PV modules become the customer's standard individually packed in cardboard boxes and horizontally stacked on wooden pallets. To secure the stack of individual packages against slipping, he is through tension bands connected to the pallet.

The general method of transport packaging of PV modules described here is associated with serious disadvantages:
On the one hand, this can only be stacked up to a limited stack height. Because the adding weight load of the stacked modules is transferred to the lowest lying modules.

to static load comes the dynamic load during transport - for example by hard settling with the forklift, acceleration, deceleration and centrifugal forces in truck transport and, above all, shocks when driving over sleepers and potholes. All this can easily damage the paper if stacked too high or the lowest module or module.

packaged PV modules are therefore rarely transported in stack heights of more than 1 m.

Because of the risk of overloading below is also the stacking of 2 loaded pallets impossible. As a result, the loading height of a truck loading bay is often only can be partially used.

To the other causes the unpacking of the individually cardboarded modules the end user a considerable amount of work. Come in addition Finally, the thankless task, considerable amounts of cardboard at the installation site if necessary, to shred and paper recycling supply.

• – auch bei hohen Stapelhöhen einen sicheren Transport gewährleistet und die Gefahr einer Beschädigung der zuunterst liegenden Module ausschließt,
• – eine Einzelverpackung der Module mit Kartonage überflüssig macht und den Verpackungsaufwand insgesamt auf das notwendige Minimum reduziert und
• – aus kostengünstig herstellbaren, möglichst einheitlich geformten und möglichst kleinteiligen, sehr stabilen Einzelelementen besteht, die an den Modulhersteller zurückgesandt und in einer hohen Zahl von Umläufen wieder verwendet werden können.

From the considerations presented here, the inventive task was to provide a packaging or transport security system for PV modules, which:

• - Ensures safe transport even at high stack heights and eliminates the risk of damage to the lowest lying modules,
• - makes a single packaging of the modules with cardboard superfluous and reduces the overall packaging costs to the necessary minimum and
• - Consists of inexpensive to produce, preferably uniformly shaped and possible small-sized, very stable individual elements that can be returned to the module manufacturer and used again in a high number of rounds.

To solve this problem, the invention proposes a modular plug-in system for the secure storage of horizontally stacked photovoltaic Modu len during transport, the system forms load-bearing columns, each having molded part members, each of these molding members inside with a load-bearing support profile as a support device for the photovoltaic module, the top or bottom with one or more pins or a Spring and underside or top side with one or more open cavities for snug receiving the pin (s) or is equipped with a groove for receiving the spring. For ergonomic reasons, the respective molded part member is provided on the upper side with the pin or the spring and on the underside with the or the downwardly open cavities or the groove.

The Load-bearing support profile, the photovoltaic module can be connected to any To carry places, for example in the area of their sides. It will but considered beneficial, especially against the background of photovoltaic modules that have a rectangular shape when the load receiving support profiles as a support device for each serve one of the four corners of the rectangular photovoltaic module. Especially Ensure that the support profiles are secure against slipping for the photovoltaic module represent.

It Thus, in particular, a system of four load-bearing columns, in particular four load-bearing corner columns proposed. At the four corners of the modules to be stacked four columns arranged, which have the task of adding weight load of the PV modules and outside of the PV modules to a derive the supporting pallet.

The four columns have the modular, uniformly shaped molding members. Each of these limbs has the task, one quarter of the weight of a single PV module and transfer it to the column. By a simple mechanical connector is each member with the adjacent Link connected.

The modular molding members thus form, put together, one heavy-duty support column. The non-shift connection of each molding member with the adjacent member is via a Plug-in mechanism achieved, for example via a pin-cavity construction. Each of the molding members is internally loaded with the load Supported profile, in which the PV module, in particular in Area of the respective corners, is inserted accurately. On the support profile Only relatively low weight and dynamic loads act.

According to one advantageous design, the molding members have a right angle angular Shape up. According to one advantageous, alternative design is provided that the Formed members form a round support column. The plug connection takes place in each case via only one pin and one Cavity. In addition to an angular or round shape of the support column also triangular, square or polygonal shapes possible.

Further Features of the invention are described in the subclaims, the following description, the refers in particular to the description of the figures, as well as the figures themselves, it being noted that all individual features and all combinations of individual features are more inventive Embodiments represent.

In the figures, the invention with reference to several embodiments explains without being limited thereto to be. It shows:

1 a first embodiment of a molding member, in a spatial view, seen obliquely from below,

2 this in 1 shown molding member, in a spatial view, seen obliquely from above,

3 two stacked molding members according to the embodiment of the 1 and 2 in which the lower molded part member accommodates a rectangular photovoltaic module in the region of a corner which is only shown in the corner region,

4 a section through the arrangement according to 3 .

5 a second embodiment of a molded part member,

6 an arrangement of two molding members according to a third embodiment, and

7 A fourth embodiment of a molded part member.

That in the 1 to 4 shown respective molding member 1 is designed for example as a plastic injection-molded part and has a rectangular shape. The molding member 1 is inside with a load-bearing support profile 2 as support device for the photovoltaic module 3 Mistake. The supporting profile 2 is essentially a horizontal plate section 4 as well as in the region of the inner end of the plate section 4 by a vertical, upwardly directed edge portion 5 educated. Upper side, the molding member 1 four cones 6 on, with each leg section 7 of the rectangular molding member 1 two cones 6 assigned. The underside is the molding member 1 With several downwardly open cavities 8th provided, the four cavities 8th which are the leg sections 7 are assigned, the inclusion of the four pins 6 serve the underlying molding member.

From a variety of molded parts 1 can be a heavy-duty support column 9 that form in the 3 and 4 only with respect to two superimposed molding members 1 is illustrated. The shift-proof connection of each molded part member 1 with the adjacent molding member 1 is achieved by the plug-in mechanism, which is realized in this embodiment by the pin-cavity construction. The modular plug-in system forms four load-bearing corner support columns 9 , being in the supporting profiles 2 the support pillars 9 the PV module 3 with its four corners is inserted accurately.

The design of the inside support profile 2 of the molding member 1 depends on whether the modular plug-in system according to the invention the transport security of framed or unframed PV modules 3 should serve.

The 3 and 4 show the example of a molded part member 1 The corner of a framed PV module 3 to record. The inside support profile 2 has the horizontal support surface 4 whose width is equal to the width of the rear frame profile 10 in the corner of the PV module to be placed 3 is tuned. The vertical edge section 5 has the function of a vertical expansion and ensures the perfect fit of the frame corner with minimal play. The vertical distance between the horizontal support profile 2 a molding member 1 and the supporting profile 2 of the adjacent molded part member 1 is by the thickness of the framed PV module 3 plus the average thickness of a human fingertip. This is an effortless lifting of the individual PV modules 3 guaranteed from the stack.

5 illustrates another useful embodiment of the modular plug-in system according to the invention, in which the basic design of the molded part member 1 the part of the molding 1 according to the embodiment of the 1 to 4 equivalent. However, in the embodiment according to the 5 instead of the four upper spigots 6 a continuous, thus right-angled spring 11 and instead of the lower cavities 8th a continuous, angled groove 12 intended. When nesting the molding members 1 grab the groove 12 of the upper molding member 1 in the spring 11 of the lower molded part member 1 one.

Either is in pin-cavity connectors as well as tongue and groove connections it is beneficial for the handling of the system when pin or spring slightly conical shaped and rounded at the edges or bevelled.

The right angle angular shape of the molded part members shown in the figures discussed so far 1 represents a useful, but not the only possible form of the modular connector system according to the invention for the transport security of stacked PV modules. A further advantageous design of the molded part members is in the 6 and 7 illustrated.

6 shows two molding members 1 , which together form a round support column. The plug connection takes place in each case via only one lower pin 6 and an upper cavity 8th , In addition to an angular or round shape of the support column also triangular, square or polygonal shapes are possible.

In the embodiment of the 6 is the molding member 1 also formed as a plastic injection molded part. The supporting profile 2 has the lower Plat tenabschnitt 4 and the outer, the connection to the hollow cylinder section 13 of the molding member 1 performing vertical edge section 5 on. The outer diameter of the pin 6 is on the inner diameter of the hollow cylinder portion 13 matched, so that the pin 6 with little play in the cavity 8th of the adjacent molded part member 1 can be inserted.

The supporting profile 2 according to the embodiment of the 6 may well be the corner of an unframed PV module 3 take up.

7 shows the example of a molded part member 1 which is to pick up the corner of an unframed PV module. The inside support profile 2 is here in the form of two horizontal webs running parallel over the corner 14 educated. The corner of the unframed PV module is between these two bars 14 inserted.

For a safe load transfer from the horizontal support profile 2 on the support column, the support profile should be designed thick-walled in the transition region from the horizontal to the vertical than in the horizontal load receiving area. This is in particular to the embodiment according to the 1 to 4 shown. It shows a material and weight-saving design. Here is the support profile 2 relatively thin-walled formed, however, is underside with vertical support ribs 15 supported.

Also, the molding members themselves can be designed to save material by - in addition to the required for the recording of pegs open cavities - more vertical, down offe ne hollow chambers included.

• – dass – vor allem bei winkelförmigen Tragsäulen – alle vertikalen Kanten der Formteil-Glieder abgerundet oder abgeschrägt sind, um sie bei Be- und Entladevorgängen unter sehr beengten Bedingungen gegen „Anecken" zu schützen.
• – und dass die Formteil-Glieder oberseitig mit einer Nut oder Kantenfase ausgestattet sind, die der Aufnahme bzw. Führung von Spannbändern dient.

Further optional design features of the modular plug-in system according to the invention are:

• - That - especially in angular support columns - all vertical edges of the molding members are rounded or beveled to protect them during loading and unloading under very tight conditions against "ticks".
• - And that the molding members are provided on the upper side with a groove or Kantenfase, which serves to accommodate or guide straps.

One Another component of the invention is the option of load-bearing Pillar system off To supplement molded parts by basic links, in particular the 4 columns through 4 basic links to complete. Such a base member is used to adjust a column or her lowest plug on the carrier pallet.

The Base member consists of a small-format plate, the upper side with one or more pins or a spring and underside equipped with corresponding downwardly open cavities or a groove is. The plate of the base member is perforated, so they on the support pallet nailed or screwed on.

By This embodiment is the base member also for attachment to the upper molding member suitable to - when stacked by two loaded Pallets - that To fit accurately fitting the second pallet.

All Parts of the modular invention Plug-in systems are advantageously produced by injection molding and consist of unfilled or mineral filled thermoplastic, substitute of light metal.

Examples

for the application of the modular invention Plug-in system and its advantages:

EXAMPLE 1

Task: 150 framed standard PV modules each with 1 square meter area for the Shipping from module manufacturer to customer safe for transport become.

A: Solution of the task according to the conventional packaging method Steps:

• 1. Each of the 150 PV modules is individually with Corrugated cardboard and adhesive tapes packed up.
• 2. A maximum of 15 individually packed modules are placed on a wooden pallet flush stacked (no standard pallet, but an industry-standard special pallet, based on the surface dimensions of the product is tuned).
• 3. The loaded pallet is secured with straps. The height of each which is 10 stacks on pallet about 90 cm.

balance:

The Working time for The 3 steps, based on 150 PV modules, is 5 hours of work.

Of the Consumption of packaging material (without adhesive and tension band) is 10 pallets and about 330 square meters of cardboard.

B: Solution of the task using of the modular invention plug-in system

Steps:

• 1. In the 4 corner regions of the special pallet 4 molded part members according to the invention are placed. On the inside, the molded part elements have a support profile for accurately fitting the rear frame profile in the corner area of the framed PV module. (see. 1 - 4 ) A first (unpacked) PV module is hooked into the molding members. Then another 4 molded parts are each attached to the lower molding members. Then the next (unpacked) PV module is hung. Another 4 molded parts are attached to the underlying mold part members. The next (unpacked) PV module is hung ... etc ... etc. The simple process is repeated until per pallet 25 PV modules are mounted in the 4-column system formed from the molding members and the stack height ( incl. pallet) approx. 160 cm.
• 2. Each of the thus formed 6 palletized stacks is cardboarded and secured with strap.

balance:

The Working time for The work steps, based on 150 PV modules, is 1.25 Worker hours.

Of the Consumption of packaging material (without strap) is 6 pallets and about 45 square meters of cardboard. In addition, there are 600 molded part members according to the invention, which are in the deposit system back brought and be reused about 50 times.

C: balance sheet comparison between A and B

The Use of the modular invention Plug system saves against the conventional one Transport Packaging 3.75 Workers Hours Working Time, 4 Wooden Pallets and about 280 square meters of cardboard.

the is an additional Material requirement of 600 reusable molded part members according to the invention across from. At 50 times circulation this corresponds to a material consumption of 12 molding members.

EXAMPLE 2

Task: Unframed standard PV modules are intended for shipment by the module manufacturer to the customer are packaged transport safe.

The conventional Packaging process corresponds here essentially to the version A in Example 1.

When using the modular plug-in system according to the invention, the object is achieved by molding members are used, the support profile is formed in the form of 2 parallel over-extending horizontal webs (see. 7 ).

In In this case, 4 such mold members first each on the 4 corners of the unframed PV module plugged in and then together with the PV module on the Set the pallet or, as a result, place it on the 4-column stack that is growing upwards.

The Advantages in terms of working time and packaging material savings essentially correspond to Example 1.

EXAMPLE 3

Task: The loading height a truck should be stacked by stacking be used by each of 2 palletized stack packs.

at Application of the conventional packaging method (described in Example 1) is this task not solvable, because the individually packed PV modules on the lower pallet would loaded inadmissible by placing a second pallet stack.

The Risk that in particular the underlying PV modules under the damaged during transport dynamic loads are damaged, would be very high.

On the other hand allowed the use of the modular invention Plug-in system stacking of two (for example, each 1 m high) palletized stacks, as the Molded parts formed 4-column construction for correspondingly high Loads is designed.

EXAMPLE 4

Task: 20 PV modules each with 1 square meter area should be taken from the pallet or unpacked at the assembly site.

A: Solution of the task according to the conventional potting method

The PV modules are - individually carton - on 2 pallets delivered.

The straps are removed, each module is unpacked individually. 2 pallets and about 45 square meters of cardboard come to disposal.

B: Solution of the task using of the modular invention plug-in system

The PV modules are installed on a - in their entirety cardboard - pallet unit delivered. The tension bands and the carton will be removed. The unpackaged PV modules will be individually lifted.

The Shaped parts of the support columns are successively "picked" and land in supplied small Cartons for the return for reuse.

1 Pallet and about 6 square meters of cardboard come to disposal.

Claims (14)

Modular plug-in system for the secure storage of horizontally stacked photovoltaic modules ( 3 ), the system consisting exclusively of individual vertical, load-bearing columns ( 9 ) is formed, each consisting of molding members ( 1 ), which are arranged one above the other and inserted into each other, the respective column ( 9 ), each of these molding members ( 1 ), on the side facing the photovoltaic module ( 3 ), with a load-bearing support profile ( 2 ) as a support device for the photovoltaic module ( 3 ), on the upper side or on the underside with one or more pins ( 6 ) or a spring ( 11 ) and underside or upper side with one or more open cavities ( 8th ) for the accurate recording of the pin (s) ( 6 ) or with a groove ( 12 ) for receiving the spring ( 11 ) Is provided. The system of claim 1, wherein there are four lastab supporting columns ( 9 ), in particular four load-bearing corner columns ( 9 ). System according to claim 1 or 2, wherein the photovoltaic module ( 3 ) is rectangular. Plug-in system according to one of claims 1 to 3, wherein the load-bearing columns ( 9 ) have round, square or rectangular cross-section. Plug-in system according to one of claims 1 to 4, wherein it is used for securing transport of framed photovoltaic modules ( 3 ) and the supporting profile ( 2 ) of each molded part member ( 1 ) on the frame profile in the corner region of the photovoltaic module ( 3 ) is tailored precisely. Plug-in system according to one of claims 1 to 4, wherein it is used for securing transport of unframed photovoltaic modules ( 3 ) and the supporting profile ( 2 ) of each molded part member ( 1 ) of two parallel horizontal webs ( 14 ) between each one corner of the unframed photovoltaic module ( 3 ) is accurately inserted. Plug-in system according to one of claims 1 to 6, wherein the support profile ( 2 ) underneath with vertical supporting ribs ( 15 ) is configured. Plug system according to one of claims 1 to 7, wherein the pins ( 6 ) or springs ( 11 ) of the molded part members ( 1 ) are rounded or beveled at the horizontal and vertical edges. Plug system according to one of claims 1 to 8, wherein the pins ( 6 ) or springs ( 11 ) of the molded part members ( 1 ) are slightly conical. Plug system according to one of claims 1 to 9, wherein all vertical edges of the molded part members ( 1 ) are rounded or bevelled. Plug system according to one of claims 1 to 10, wherein the molded part members ( 1 ) are solid or - in addition to those for receiving the pins ( 6 ) required open cavities ( 8th ) - vertical, to the adjacent molding member ( 1 ) open hollow chambers ( 8th ) contain. Plug-in system according to one of claims 1 to 11, wherein the vertical distance between the horizontal support profile ( 2 ) of a molded part member ( 1 ) and the horizontal support profile ( 2 ) of the molded part member ( 1 ) the thickness of a framed photovoltaic module ( 3 ) plus the average thickness of a human fingertip. Plug system according to one of claims 1 to 12, wherein the molded part members ( 1 ) are equipped on the upper side with a groove or Kantenfase for receiving tension straps. Plug-in system according to one of claims 1 to 13, wherein all molded part members ( 1 ) are made by injection molding and consist of unfilled or mineral-filled thermoplastic or light metal.