JP7493789B2 - Solar panel installation structure and its fixings - Google Patents

Description

This invention relates to a solar panel installation structure that fixes a solar panel onto a sloped roof panel.

A mounting system is used to secure the solar panel to the roof shingles. That is, the mounting system is fixed to the top surface of the roof shingles, and the solar panel is supported by the mounting system.

The following Patent Document 1 is one of them.

The solar panel support bracket in Patent Document 1 is composed of a main bracket, a back clamp, a front clamp, and two sets of bolts and nuts. The main bracket has an installation piece that is adhesively fixed to the top surface of the roof panel, a standing piece that stands vertically from one end of the installation piece, and a support part that extends horizontally from the top end of the standing piece.

To secure a solar panel, first secure the solar panel support bracket to the frame of the solar panel. That is, the frame located on the outer periphery of the solar panel is placed on top of the support part of the main bracket, and the bottom edge of the frame is clamped and fixed with a back clamp. Next, the top surface of the solar panel frame is engaged with a front clamp fixed to the upright piece with a bolt and nut, and the frame is clamped between the front clamp and the support part. After this, the installation piece of the main bracket is fixed to the top surface of the roof with a double-sided adhesive sheet.

Solar panel installation structures using such solar panel support brackets allow for easy installation of solar panels.

Registered Utility Model No. 3228655

However, solar panel support brackets are designed to support the solar panel at a position above the top surface of the roof panel using an upright piece and a support section. In addition to the solar panel's own weight, it is also subjected to loads from wind, snow, etc. For this reason, the load on the adhesively fixed installation piece that supports the upright piece is large.

Therefore, the main objective of this invention is to reduce the load placed on the attachment points between the roof panels and the components used to attach the solar panel.

The means for achieving this is a solar panel installation structure that fixes a solar panel onto a roof plate, the roof plate having a shape with peaks and valleys, the solar panel is placed directly on the top surface of the peaks, and the edge of the solar panel is pressed downward using a solar panel fixture that includes a main body member having a fixing part fixed to the top surface of the roof plate and a bolt holding part erected upward from the fixing part, and a pressing member that is tightened to the bolt holding part using a bolt.

In this configuration, the solar panel fixture does not support the solar panel as a stand, but rather the weight of the solar panel is supported by the roof plate, and the solar panel fixture clamps the edge of the solar panel between the roof plate and the solar panel fixture. The solar panel fixture's clamping member clamps the solar panel between the roof plate and the bolts, so a constant fixed state is obtained without being affected by the mounting height of the main body member.

According to this invention, the solar panel is supported by the roof panel, so the load on the fixing part of the solar panel fixture can be reduced. Therefore, even if it is subjected to wind pressure or weight from accumulated snow, the solar panel fixture does not deform and can maintain its fixed state. Furthermore, the solar panel fixture is composed of a main body member and a pressing member, and the solar panel is fixedly fixed between the pressing member and the roof panel, so a strong fixed state can be obtained from this point of view as well.

FIG. FIG. 2 is a plan view of the solar panel installation structure. FIG. FIG. FIG. FIG. 4 is a cross-sectional view of the solar cell panel in a fixed state. FIG. 4 is a cross-sectional view of the solar cell panel in a fixed state. FIG. 4 is a cross-sectional view of the solar cell panel in a fixed state. FIG. 11 is a front view of a solar cell panel installation structure according to another example. 11 is a perspective view of a body member of the solar panel fixture shown in FIG. 10 . FIG. 11 is a partial cross-sectional front view showing a separated state of a solar cell panel fixing device according to another example.

One embodiment of the invention is described below with reference to the drawings.

Figure 1 shows a front view (view of the roof from the eaves side) of the solar panel installation structure in which a solar panel 21 is fixed onto a roof panel 11, and Figure 2 shows a plan view (view of the roof from above).

This solar panel installation structure is a structure in which the solar panel 21, which is placed directly on the upper surface of the roof plate 11, is pressed down and fixed with a solar panel fixing device 31 (hereinafter referred to as the "fixing device") fixed to the upper surface of the roof plate 11. For this reason, the fixing device 31 includes a main body member 32, a pressing member 33, and a bolt 34.

The main body member 32 is composed of a fixing part 35 that is fixed to the upper surface of the roof panel 11, and a bolt holding part 36 that stands upright from the fixing part 35. The pressing member 33 is tightened toward the bolt holding part 36 by a bolt 34. When fixing, the pressing member 33 presses the edge of the solar cell panel 21 downward, and clamps the solar cell panel 21 between the pressing member 33 and the roof panel 11.

The roof panel 11 shown in Figures 1 and 2 is a corrugated slate, and has peaks 12 and valleys 13, each of which has a roughly semicircular cross section, repeated in the left-right direction. The peaks 12 and valleys 13 are continuous via an inclined surface 14. Note that the corrugated slate is one example of the roof panel 11, and the roof panel 11 may be something other than a corrugated slate.

To give a very simple explanation of the solar cell panel 21, the solar cell panel 21 is rectangular in plan view and has a frame 22 around its entire perimeter. The frame 22 has a U-shaped cross section and has an upper surface 22a facing upward, a lower surface 22b located on the back side, and a vertical end surface 22c that connects these at the outer end.

As shown in FIG. 2, multiple fasteners 31 are used to fasten one solar panel 21. For example, when the solar panel 21 is installed horizontally in a direction perpendicular to the slope of the roof shingles 11 as in the illustrated example, multiple fasteners are arranged on each of the two long sides located above and below. When the solar panel 21 is arranged in the slope direction of the roof shingles 11, two adjacent solar panel 21 are fastened by one fastener 31 attached between the solar panel 21.

As described above, the fixture 31 has a main body member 32, a pressing member 33, and a bolt 34 that connects them, and FIG. 3 is an exploded perspective view of the fixture 31. Note that the fixture 31 shown in FIG. 3 is disposed between the solar cell panels 21 that are lined up in the gradient direction, and the pressing member 33 shown in FIG. 3 is dedicated to that purpose. For the fixtures 31 that are disposed at the top and bottom ends of the solar cell panels 21 that are lined up in the gradient direction, pressing members 33 of a different shape than the one shown in FIG. 3 are used.

To explain the fixing device 31 in detail, the main body member 32 is composed of a single pressed metal plate. The metal plate may be an aluminum alloy, a stainless steel alloy, or a galvanized steel plate. The fixing device 31 may be obtained by molding not only a metal plate but also a synthetic resin or a thermoplastic fiber-reinforced material.

The fixing part 35, which is fixed to the upper surface of the roof panel 11, is fixed so as to straddle the peak portion 12 of the roof panel 11, and has a pair of fixing part carriers 37 on the left and right.

The fixed part carrier 37 is fixed to the roof panel 11 by adhesion. For this reason, the fixed part carrier 37 is formed in a plate shape of an appropriate size that matches the surface shape of the adhesion site. The adhesion sites of the pair of fixed part carriers 37 arranged at a distance on the left and right are the peaks 12 of the roof panel 11 and the side surface continuing from the peaks 12. As mentioned above, since the roof panel 11 is corrugated, the fixed part carrier 37 has a curved portion 37a that overlaps the part of the peaks 12 that has an approximately arc-shaped cross section, and a flat portion 37b that overlaps the inclined surface portion 14 that continues from the peaks 12 to the valleys 13.

The height of the upper end of the fixing portion 35, specifically the fixing portion support 37, is set to a height that is equal to or lower than the height of the top surface of the peak portion 12 when fixed to the roof panel 11, as shown in FIG. 1. In other words, the fixing portion support 37 and the space between them in the fixing portion 35 other than the portion having the bolt holding portion 36 allow the solar panel 21 to come into contact with the top surface of the peak portion 12 of the roof panel 11 when the solar panel 21 is placed on it.

The fixing portion 35 (fixing portion support 37) is formed long in the front-to-rear direction, which is the gradient direction of the roof panel 11. The length should be long enough to ensure a sufficient adhesion area, and from another perspective, it is preferable that it is formed longer than the distance between adjacent solar cell panels 21.

The bolt holding portion 36 is integrally formed at a portion of the longitudinal direction of the fixed portion carrier 37, specifically at the middle position, which is a rectangular plate-like shape.

The bolt holding portion 36 has a pair of left and right standing pieces 38 continuing from the fixing portion carrier 37, and a connecting piece 39 connecting the upper ends of the standing pieces 38. The standing pieces 38 and the connecting piece 39 have the same length in the front-rear direction, which is the gradient direction of the roof panel 11. The front-rear and left-right lengths of the connecting piece 39 are set to a length that allows tightening by the bolt 34, that is, the diameter of the head of the bolt 34 or the diameter of the nut 34a or washer screwed onto the bolt 34, whichever is larger. In particular, the front-rear length of the connecting piece 39 is set to the same as the distance between adjacent solar cell panels 21 in the gradient direction of the roof panel 11. From the viewpoint of narrowing the distance between the solar cell panels 21, it is better for the bolt holding portion 36 to have a shorter front-rear length.

As described above, the length of the standing piece 38 and the connecting piece 39 in the front-to-rear direction is the same as the distance between adjacent solar cell panels 21 in the slope direction of the roof panel 11, so the front-to-rear end faces of the standing piece 38 and the connecting piece 39 become abutment surfaces 38a, 39a that abut against the end face 22c of the solar cell panel 21. The bolt holding portion 36 may be shaped so that only one of the standing piece 38 or the connecting piece 39 has the abutment surface 38a, 39a.

The height of the connecting piece 39 is set so that it is lower than the top surface position (thickness) of the frame 22 of the solar panel 21 that is placed on the top surface of the roof panel 11 when the fixing part 35 is fixed to the roof panel 11, and is a height that can accommodate the head of the bolt 34 between the connecting piece 39 and the top surface of the roof panel 11.

The bolt holding portion 36 shown in FIG. 3 is for inserting and holding the base of the bolt 34, and has a through hole 40 formed in the center for inserting the bolt 34. The bolt 34 can also be fixed integrally to the through hole 40. Also, for example, a square bolt can be used for the bolt 34, and the through hole 40 can be a square hole.

The pressing member 33 is formed in a flat shape from a single metal plate, and has a pressing portion 41 that overlaps the upper surface 22a of the frame 22 of the solar cell panel 21. Specifically, the pressing member 33 has a rectangular shape in a plan view that is long in the front-to-rear direction corresponding to the gradient direction of the roof panel 11, and has pressing portions 41 at both ends in the longitudinal direction. An insertion hole 42 for inserting the aforementioned bolt 34 is formed in the center of the pressing member 33, that is, in the middle position between the pressing portions 41.

The length of the retaining member 33 in the direction corresponding to the left-right direction of the roof panel 11 is equal to or greater than the length that allows tightening by the bolt 34, similar to the bolt retaining portion 36 described above. The length in the front-rear direction corresponding to the gradient direction of the roof panel 11 is set to be equal to the distance between the inner ends of the upper surface 22a of the frame 22 of the solar cell panels 21 adjacent in the gradient direction of the roof panel 11 (see Figure 2).

The pressing member 33 may be provided with a structure to prevent co-rotation. Although not shown in the figure, for example, a restricting claw protruding downwards may be provided on both the left and right edges of the pressing member 33. Two restricting claws are formed on each of the left and right edges, and the distance between the restricting pieces aligned in the front-to-rear direction is set taking into account the distance between adjacent solar cell panels 21 in the slope direction of the roof panel 11. Also, a hammered protrusion may be provided in place of the restricting claw.

The clamping member 33 used in the fastener 31 arranged at both the top and bottom ends of the roof panel 11 in the gradient direction has a structure that has a clamping portion 41 on only one side, and is basically the same structure as the clamping member 33 shown in Figure 3.

The fasteners 31 arranged at both the top and bottom ends of the roof panel 11 in the gradient direction are the same as the main body member 32 and the like described above, except for the retaining member 33, but the contact surfaces 38a, 39a of the bolt holding portion 36 are only contact surfaces 38a, 39a on one side, not both, in the front-to-rear direction.

The above-described fixture 31 is used as follows to form a solar panel installation structure.

First, as shown in Figure 4, multiple fasteners 31 are glued and fixed at predetermined positions on the top surface of the roof panel 11. At this time, bolts 34 are held in the bolt holding parts 36. The fasteners 31 are fixed using a double-sided adhesive sheet 51. As shown in an enlarged portion of Figure 5, the double-sided adhesive sheet 51 is configured such that adhesive layers 53 are integrally formed on both sides of a sheet-like substrate 52 made of, for example, a rubber sheet, woven fabric, or nonwoven fabric, and a sheet with strong adhesive power and good weather resistance is used.

The double-sided adhesive sheet 51 used is preferably cut to a shape that corresponds to the adhesive surface, which is the lower surface of the fixed part carrier 37.

Next, the solar panel 21 is placed so as to be spread out between the multiple fixtures 31 fixed to the upper surface of the roof shingle 11 (see Figures 5 and 2). The solar panel 21 is placed on the top surface of the peak 12 of the roof shingle 11, and the end surface 22c of the frame 22 is abutted against the abutment surfaces 38a, 39a of the bolt holding portion 36 of the fixture 31 to regulate its position.

Then, the bolts 34 and nuts 34a are used to tighten the pressing member 33, pressing the edge of the solar panel 21, i.e., the upper surface 22a of the frame 22, downward toward the roof panel 11. In other words, the frame 22 is sandwiched between the roof panel 11 and the pressing member 33, as shown in Figures 6, 7, and 8.

Figure 6 is a cross-sectional view taken at the midpoint between adjacent solar cell panels 21 in the slope direction of the roof panel 11, viewed in the front-to-back direction, which is the slope direction of the roof panel 11. Figure 7 is a cross-sectional view of the same part viewed from the left-to-right direction. Figure 8 is a cross-sectional view of the fasteners 31 arranged at both the top and bottom ends of the roof panel 11 in the slope direction, viewed from the left-to-right direction.

In this way, the solar panel 21 is placed directly on the roof plate 11, and this state is maintained by the fixing device 31 pressing it down against the roof plate 11 and by the bolt holding portion 36 of the fixing device 31 surrounding the solar panel 21. Because the fixing device 31 does not support the solar panel 21 like a stand, the installation can be performed with reduced load on the fixing portion 35 of the fixing device 31 that is fixed to the roof plate 11.

As a result, even if the solar panel 21 is heavy, it can be firmly fixed, and even if wind pressure or load from snow is applied in addition to the weight of the solar panel 21, the fixing device 31 will not deform and can maintain a good fixed state.

Because the load on the fixing device 31 can be reduced, it is also possible to reduce the thickness of the metal plate used for the fixing device 31, which can reduce material costs. Also, while some conventional racks use long components, as mentioned above, the fixing device 31 uses fewer components and does not require long components. This also contributes to reducing manufacturing and transportation costs.

In addition, since the number of parts is small and the fixing device 31 is fixed by adhesive, construction is easy and workable, and the construction period can be shortened. Furthermore, since there is no need to drill holes in the roof shingles 11, even if the roof shingles 11 are old and contain asbestos, asbestos scattering can be prevented.

In addition, because the solar panel 21 is placed directly on the mountain portion 12 and pressed down on the mountain portion 12, a consistent fixed state can be obtained even if the fixing fixtures 31 are slightly misaligned. In other words, even if the multiple fixing fixtures 31 are not all fixed at the same height, the state of the clamped and fixed parts of the solar panel 21 can be made the same. This, combined with the reduction in the load on the fixing fixtures 31, ensures a strong fixed state.

The fixing portion 35 of the fixture 31 is formed long in the front-to-rear direction and has a bolt holding portion 36 on one side, so that at least a portion of the fixing portion 35 is located in the shade below the solar panel 21, and deterioration of that portion due to sunlight is suppressed. This also increases the durability of the fixed state by adhesion.

Other examples will be described below. In this description, the same parts as those in the configuration described above will be given the same reference numerals and detailed description will be omitted.

Figure 9 is a front view of a solar panel installation structure in which the roof panels 11 are vertically folded panels. That is, the roof panels 11 have repeated, continuous peaks 12 and valleys 13, but the tops of the peaks 12 and the bottoms of the valleys 13 are flat. Between the peaks 12 and valleys 13 is a linear inclined surface 14.

The main body member 32 of the fixture 31 is formed to match the shape of the roof panel 11. That is, the fixing portion 35 of the main body member 32 has a pair of fixing portion supports 37 spaced apart from each other, as shown in the perspective view of FIG. 10, and these fixing portion supports 37 are set at the same inclination angle as the inclined surface portion 14 of the roof panel 11.

The bolt holding part 36 is provided in the middle of the fixed part support 37 in the longitudinal direction, and the upright piece 38 of the bolt holding part 36 has the same inclination angle as the fixed part support 37. The upright piece 38 may be made to stand vertically, but this would require an additional bending process, which would increase costs.

The components of the fixture 31 other than the main body member 32 are the same as described above.

The fixing device 31 having such a configuration is used in the same manner as described above to form a solar panel installation structure.

Figure 11 shows another example of the bolt holding portion 36 in the main body member 32. That is, while the bolt holding portion 36 described above was an example in which the base of the bolt 34 is inserted and held, the bolt holding portion 36 in Figure 11 has a structure in which the tip of the bolt 34 inserted from above is screwed into it.

For this reason, not only is a through hole 40 formed in the connecting piece 39 of the bolt holding portion 36, but a nut 34a is fixed to the underside of the connecting piece 39. The nut 34a can be, for example, a clinch nut. It may also be a normal nut and fixed by welding or the like. A female thread can also be directly formed by burring and tapping.

When using a fastener 31 with this configuration, there is no need to use bolts when fastening the main body member 32 to the roof panel 11, making the work easier. The nut 34a fits inside the bolt holding portion 36, so it does not become bulky and the number of parts required for the fastening work can be reduced.

In addition, although not shown in the figures, the roof panel 11 may be of another type of roof, such as a tile roof.

The fixing device 31 may be fixed with adhesive instead of the double-sided adhesive sheet 51.

The length of the fixing portion 35 of the fixing device 31 in the front-rear direction may be the same as the length of the bolt holding portion 36 in the corresponding direction, or it may be shorter.

The relationship between the fixing portion 35 and the bolt holding portion 36 of the fixture 31 can be such that the bolt holding portion 36 is shifted to one side in the longitudinal direction of the fixing portion 35. In this case, it is preferable that the fixing portion 35 is positioned below the solar panel 21 when the solar panel 21 is installed.

The fixing portion 35 of the fixing device 31 may be fixed to the valley portion 13 of the roof panel 11.

Reference Signs List 11 roof panel 12 peak portion 13 valley portion 21 solar cell panel 31 fastener 32 main body member 33 pressing member 34 bolt 35 fastening portion 36 bolt holding portion 37 fastening portion carrier 38a, 39a contact surface 51 double-sided adhesive sheet

Claims (6)

A solar panel installation structure for fixing a solar panel onto a roof plate,
The roof shingle has a shape having peaks and valleys,
The solar cell panel is placed directly on the top surface of the mountain portion,
A solar cell panel installation structure in which the edge of the solar cell panel is pressed downward using a solar cell panel fixing device having a main body member having a fixing portion fixed to the upper surface of the roof panel and a bolt retaining portion erected upward from the fixing portion, and a pressing member which is tightened to the bolt retaining portion using a bolt. 2. The solar cell panel installation structure according to claim 1, wherein the fixing portion of the solar cell panel fixing device is fixed to the roof plate by adhesive. 3. The solar cell panel installation structure according to claim 1, wherein the bolt holding portion of the solar cell panel fixing device restricts an end face of the solar cell panel. A solar cell panel fixture that is attached to a roof plate having a shape with peaks and valleys and fixes a solar cell panel,
A main body member having a fixing portion fixed to an upper surface of the roof panel and a bolt holding portion erected upward from the fixing portion;
A solar cell panel fixing device comprising a pressing member that is fastened to the bolt retaining portion with a bolt and presses downward the edge of the solar cell panel that is placed directly on the top surface of the ridge portion of the roof panel. The bolt holding portion is formed at a part of the fixing portion in the longitudinal direction,
The fixed portion is composed of a pair of left and right fixed portion carriers,
5. The solar cell panel fixing device according to claim 4, wherein the height of the upper end of the fixing portion support other than the bolt holding portion is set to be equal to or lower than the height of the top surface of the ridge portion of the roof panel. The bolt holding portion has a pair of left and right upright pieces and a connecting piece connecting upper ends of the upright pieces,
6. The solar cell panel fixing device according to claim 4, wherein a front-rear end surface of at least one of the standing piece and the connecting piece is set as a contact surface that contacts an end surface of the solar cell panel.

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