DE9204018U1 - Profile rail combination as a structural element for substructures of solar energy converter systems - Google Patents

Description

Description: The invention relates to:

title

State of the art:

Profile rail combination as a construction element for substructures of solar energy converter systems.

When setting up solar energy converter systems, the individual converters, also called modules, must be lined up, fixed and connected to one another, taking into account specifications (e.g. desired output, usable area, solar radiation parameters, etc.).

The modules are usually attached to substructures, also called "frames", "solar frames" or "roof frames". These in turn are placed on the substructures, e.g. roof trusses, foundations, scaffolding, and connected to them in a force-fitting manner, usually using so-called "solar support elements". The solar support elements are available in various designs (roof support tubes, modified grid supports, etc.). The substructures have previously been assembled from individual rails of various commercially available profile types.

The current state of the art is evident from the following publication: "Installation of photovoltaic systems as part of the federal-state 1000 roofs photovoltaic program", published in July 1991 by TüV-Rheinland, PO Box 90 30 60, 5000 Cologne 90, Section 5., Roof constructions. (A new edition, but without changes in Section 5, is in preparation).

In a publication by Telefunken from February 1991, the use of individual C-profile rails is mentioned, see: "Technical training for photovoltaic systems", Publisher: Telefunken Systemtechnik GmbH, Department of New Technologies, Industriestraße 23 - 33, 2000 Wedel (Holstein), Tel. 04103/60-0.

- Sheet

Gerhard Töfflinger Kiefernweg 51 3500 KASSEL

Gbm registration from 4 March 92

Continued: State of the art:

This publication also addresses the use of so-called "Halfeneisen rails and screws". This is a modified C-profile rail (product of Halfeneisen GmbH & Co, Harffstraße 47-51, 4000 Düsseldorf 13) which, in conjunction with special screws, prevents them from twisting when tightened.

Here, too, no application of a profile rail combination with openings (as in this application) is mentioned.

Problem:

When installing solar energy converter systems, the assembly effort is considerable. It is therefore desirable to minimize these labor costs. For good assembly preparation in the workshop, it is absolutely necessary to have exact connection dimensions of the substructure. And here there is a difficult problem. Almost always, e.g.: even in the 1000 roofs program, the houses have been completed for some time. However, you need exact connection dimensions of the roof truss construction. In order to be able to take these measurements, the roof would have to be uncovered. Since the costs for this are considerable, this is not done in practice. The usual procedure today is that the roof is only uncovered when assembly begins and the adjustment work on the substructure is then carried out on site. The labor required for this is relatively large. The aim is to keep it as low as possible. It is also disadvantageous if the roofs have to remain open for a long time.

Another problem is optimizing the position of the solar modules in relation to the sun's rays. Shading problems often occur, which must be avoided at all costs (shaded modules consume energy). Modules cannot be installed in places where there are roof penetrations.

- Sheet 6 -

Gerhard Töfflinger Kiefernweg 51 3500 KASSEL

Gbm registration of 4 March 92

Continuation of problem:

These include roof windows, chimneys, antennas, ventilation systems.

For these reasons, it is very advantageous to be able to move the modules even after assembly without a great deal of work.

Invention:

This problem is solved by the measures of claim 1.

Beneficial effects:

The invention enables the substructure to be highly adaptable to the existing connection dimensions of the substructure, with little work required on site.

As before, the so-called "solar support elements" (these are available in various designs, they are usually standpipes or modified walkway supports) are first attached to the substructure, often the roof truss. These elements are passed through the roof by replacing a roof tile with a commercially available roof duct (e.g. antenna duct). This achieves the required tightness. At the same time, this also results in the necessary alignment of the elements in the longitudinal direction of the rail. Once this preparatory work has been completed, the profile rail combinations can be laid on after they have been cut to the correct length and attached to the solar support elements using fastening elements (e.g. hexagon socket screws with washers). This creates the connection between the substructure and the substructure (solar support frame).

- Sheet 7 -

Gerhard Töfflinger Gbm-Registration

Kiefernweg 51 from 4 March 92

KASSEL

Continued Beneficial Effects:

Unfortunately, the distance between the profile rail combinations, which results from the division of the roof tiles (tiles), does not or very rarely match the distances determined by the modules. Therefore, a second layer of profile rails is required, which is best laid at a right angle to the first layer.

The distance specified by the fastening connections of the modules must be observed as the distance for the upper layer of the rails. The force-fit connection of the two layers is easy to establish, as the fastening elements can be pushed to any position without drilling. Finally, the modules are placed on the upper layer of the rails and also fastened to the desired positions using sliding fastening elements. Particularly when there are internal threads on the solar support elements or on the modules, but also when connecting two layers of C-profile rails to one another, it is necessary that a tool can be pushed through the side opposite the open side of the C-profile rail. This makes it possible to tighten or loosen a fastening element (e.g. a hexagon socket screw). The openings, see item (4), are necessary for this. However, these can also be used to insert and remove power cables that are to be laid in a protected manner in the rails.

In summary, the assembly process is designed so that the length of the profile rail combinations is determined before assembly begins, i.e. before the roof is uncovered. The rails can then be cut to length in the workshop. Attaching the

- Sheet

Gerhard Töfflinger Kiefernweg 51 3500 KASSEL

Gbm registration of 4 March 92

Continued beneficial effects:

Solar support elements on the substructure (e.g. roof truss) are usually installed by the roofer and are preparatory work. The rails are simply laid on the construction site (1st layer) and secured. Then comes the second (upper) layer of profile rail combinations, mainly at right angles, and this is secured to the lower layer. The modules can then be laid on and secured. So no more measurements need to be taken during installation and no more drills or saws are needed. Working with electric hand tools, which is unpleasant due to the weight and the electrical supply lines and poses a safety risk, can be eliminated.

Considerable savings in working time and materials are expected. The risk of accidents will also be reduced.

Further development of the invention:

Advantageous embodiments of the invention are specified in claims 2 to 7.

The further development according to claim 2 brings an improvement in the assembly of the modules if they are provided with an internal thread.

The further development according to claim 3 results in the modules being placed at a greater distance from the substructure (roof). This enables improved rear ventilation (cooling), which improves the efficiency of photovoltaic systems.

In claim 4, ease of assembly for modules is achieved when they have to be fastened with brackets.

The further development according to claim 5 is advantageous for increasing the strength values.

Sheet 9 -

Gerhard Töfflinger Gbm-Registration

Kiefernweg 51 from 4 March 92

KASSEL

Continuation of the invention:

The design according to claim 6 results in material savings, since the third fastening option is not required for edge rails.

The further development according to claim 7 can bring cost savings when larger quantities are required.

Description of the invention:

Fi gurenbe-

Description: Explanation of position numbers, valid for all figures:

Pos. 1 = C-profile rail

Pos. 2 = C-profile rail

Pos. 3 = C-profile rail

Pos. 4 = Openings along the center line of the side opposite the open side of the C-profile rail

Pos. 5 = Overall profile made from one piece 1

Embodiments of the invention are explained using the following figures:

Determination:

For figures 1 to 8, all profile rails are parallel and are directly or indirectly firmly connected to one another.

Figure 1: Perspective view of a profile rail combination made up of three adjacent C-profile rails (1), (2) and (3). The openings (4) are located on the middle profile rail (2) on the side opposite the open side, along the center line.

Figure 2: The profile rails (1) and (3) are also provided with openings (4). Otherwise as in Figure 1.

- Sheet 10 -

Gerhard Töfflinger Gbm-Registration

Kiefernweg 51 from 4 March 92

KASSEL

Continued character description:

Figure 3: Sectional drawing through a profile rail combination of three C-profiles, in which the profile rails (1) and (3) lie on profile (2) and have a distance between them that corresponds approximately to the width of the opening (4) of rail (2).

Figure 4: Section through an arrangement of three adjacent profile rails. Rail (1) is angled 90 degrees

to the left and outside profile rail (3) is rotated by degrees to the right. Modules with angle fasteners can be mounted more easily this way. Rails (1) and (3) have no openings (4).

Figure 5: Section through three profile rails, arrangement as in Figure 3. Rails (1) and (3) are each turned outwards by 90 degrees. All rails have openings (4).

Figure 6: Section through a profile rail arrangement as in Fig. 3. The rails (1) and (3) are modified by the free legs being bent inwards at a right angle. Only profile (2) has openings (4).

Figure 7: Section through a C-profile rail combination similar to Figure 6. On all profiles (1), (2) and (3), the free legs are additionally bent inwards at the end.

Figure 8a: Section through a C-Profil1 rail combination made up of two profiles (2) and (3) on top of each other. Rail (1) has been omitted, the arrangement is symmetrical. The openings (4) are as congruent as possible to allow tools or cables to be passed through.

- Sheet 1 1

Gerhard Töfflinger Kiefernweg 51 3500 KASSEL

Gbm registration of 4 March 92

Continued character description:

Figure 8b: Section through a combination of two profiles (1) and (2) similar to Fig. 8a, but offset. Both profiles have openings (4).

Figure 8c: Section through a combination of two adjacent C-profiles (2) and (3), where (2) is open at the bottom and (3) at the top, e.g. for fastening the modules.

Figure 9: Section through a combination profile (5) that originally consisted of three C-profiles and was now manufactured as a whole, i.e. consists of one piece.

Claims (4)

Protection claims:
General term: 1. Profile rail combination as a construction element for substructures of solar energy converter systems, Subclaims: characterized, that three C-profile rails (1), (2) and (3) are arranged parallel to one another and firmly connected to one another in such a way that the open sides of the rails (1) and (3) point in the opposite direction to the open side of the middle rail (2), whereby this rail (2) is provided with openings (4) along the center line of the side opposite the open side (Figure 1). 2. Profile rail combination according to claim 1 characterized, that the C-profile rails (1) and (3) are also provided with openings (4) on the side opposite the open side along the centre line (Figure 2). 3. Profile rail combination according to claim or 2. characterized, that the two outer C-profile rails (1) and (3) are placed on the middle rail (2) and firmly connected to each other so that their open sides point upwards, i.e. opposite to the lower rail, (Figure 3). Page 2 - Gerhard Töfflinger Gbm-Registration Kiefernweg 51 from 4 March 92 KASSEL Continuation of the subclaims: 4. Profile rail combination according to claim 1 to 3. characterized, that the two C-profile rails (1) and (3) are each rotated outwards by 90 degrees, so that their open side faces to the left or right, (Figures 4 and 5). Profile rail combination according to claim 1 to 4. characterized, that the free legs of individual or all C-profile rails are additionally bent inwards again (Figures 6 and 7). Profile rail combination according to claims 1 to 5. characterized, that one of the two profile rails (1) or (3) is omitted (Figures 8a, 8b and 8c). - Sheet 3 - Gerhard Töfflinger Gbm-Registration Kiefernweg 51 from 4, March KASSEL Continuation of the subclaims: 7. Profile rail combination according to claims 1 to 6. characterized, that the overall profile, normally composed of individual profiles, is replaced by an overall profile consisting of one piece (Figure 9),