US20140041202A1

US20140041202A1 - Fastening System for Mounting Solar Modules on a Trapezoidal Sheet

Info

Publication number: US20140041202A1
Application number: US13/979,290
Authority: US
Inventors: Sandy Schnitzer; Lisa Hertlein
Original assignee: Mounting Systems GmbH
Current assignee: Mounting Systems GmbH
Priority date: 2011-01-12
Filing date: 2012-01-10
Publication date: 2014-02-13
Also published as: DE102011084556A1; CA2824226A1; JP5933593B2; JP2014503724A; WO2012095413A1; ZA201304267B; CN103443562A; EP2663815A1; AU2012206683A1

Abstract

A profile rail comprising in a cross-sectional view: a base plate which forms a bottom side of the profile rail and which is flat in sections or completely flat; a first and a second receiving cavity for a rail support which cavities are both partially closed laterally in outward direction and which respectively include a lateral opening, wherein the two lateral openings are oriented in opposite directions; and a third receiving cavity which includes an opening that is oriented away from the bottom side of the profile rail and which includes an inner profile for attaching module attachment elements.

Description

The invention relates to a profile rail, an attachment system for mounting solar modules on a trapezoidal sheet, an arrangement for attaching solar modules on a trapezoidal sheet and a method for mounting an attachment system according to the invention on a trapezoidal sheet.
Solar modules, for example photovoltaic modules for generating electrical energy or collector modules for heating heat transfer media are typically attached in roof or ground assemblies on profile rails that are arranged parallel to one another.
Trapezoidal sheets are typically used for roofs of industrial and commercial buildings, since the trapezoidal sheets are much stronger than flat metal plates due to their shape. Trapezoidal sheets include raised beads and adjacent flanks in a continuous metal plate, wherein the adjacent flanks protrude from beads of the trapezoidal sheet.
Known attachment systems provide an attachment of the profile rail on the raised beads of the trapezoidal sheet. For this attachment type, there is a risk that screws or rivets are torn out under strong wind loads due to material thickness typically starting at 0.5 mm.
A known attachment system for mounting solar modules on a trapezoidal sheet is being offered under the trade name VarioFix-V-System by Schletter GmbH. There a profile rail is being used which has a C-shaped inner profile at a bottom side. For mounting purposes, supports with a rectangular main element and a T-shaped component are being used, wherein the T-shaped component protrudes from a center of a long side of the rectangle and in the same plane. The supports are inserted into the C-shaped profile with the respective T-shaped components and attached with attachment devices like screws or rivets at two clearance holes at flanks of the trapezoidal sheet. Thus, the supports are entirely below the profile rail. Mounting a system of this type is cumbersome since the supports have to be inserted from below into the already contacting profile rail.
It is desirable to be able to mount solar modules on a trapezoidal sheet in a simpler manner.
A first aspect of the present invention relates to a profile rail comprising in a cross-sectional view:

- a base plate which forms a bottom side of the profile rail which is flat in sections or completely flat,
- a first and a second receiving cavity for rail supports which are both partially closed laterally in outward direction and which respectively include a lateral opening, wherein the two lateral openings are oriented in opposite directions, and
- a third receiving cavity which includes an opening that is oriented away from the bottom side of the profile rail and includes an inner profile for attaching module attachment elements.

The profile rail according to the invention facilitates particularly simple mounting of an attachment system for solar modules on a trapezoidal sheet. Rail supports can be mounted at sides of the profile rail on flanks of the raised beads of the trapezoidal sheet and can be connected with the profile rail in both receiving cavities provided for this purpose. The profile rail furthermore facilitates an attachment at the trapezoidal sheet, which allows expansions or contractions caused by temperature changes.
Based on the described features the profile rail can be mounted in a simple manner so that rail supports which can laterally engage the receiving cavities provided for this purpose contact flanks of the raised beads of the trapezoidal sheet and are connected with an attachment device like a screw or a rivet at the respective flank. The load of the trapezoidal sheet is thus performed through shearing, which facilitates introducing much higher forces into the trapezoidal sheet so that higher loads can be supported compared to the profile rail only being screwed down from above and the trapezoidal sheet only being loaded through tension.
The support is preferably attached at the flanks of the raised beads so that it is only arranged in an upper third of the flank, for example when typical trapezoidal sheets are used. Thus, a penetration directly in the water conducting bead is prevented.
The profile rail according to the present invention also facilitates a use on different profile geometries of trapezoidal sheets. This is important for variable use of the profile rail due to the plurality of embodiments of trapezoidal sheets.
The first and the second receiver cavity for rail supports are both partially closed in a respective lateral outward direction. Accordingly, the receiver cavities have a respective lateral opening towards the ambient of the profile rail. Lateral directions in the context of the instant application are directions transversal to the longitudinal rail orientation, which are not simultaneously perpendicular to the base plate.
Subsequently, embodiments of the profile rail are described.
The base plate of the profile rail preferably has a completely flat bottom side. This facilitates even contact on raised beads of a trapezoidal sheet. The base plate, however, can also be flat in sections, for example when a notch in the base plate shall be configured for fabrication and transportation reasons or when the notch in the base plate shall be used for fixating the profile rail. The bottom side of the base plate also defines a bottom side of the profile rail.
The receiving cavities for rail supports are defined in one embodiment C-shaped on an inside. Put differently, the inner defining bars of the rail supports form a C-shape in cross-sectional view. A C-shaped delimitation of this type can be facilitated in a suitable manner by three arms from which two arms are also oriented horizontally and one is oriented vertically relative to a horizontally extending base plate. When these arms are arranged at a right angle relative to one another, this yields a particularly simple, compact and stable embodiment.
The C-shape that is partially closed in outward direction facilitates using rail supports with a T-profile that engages in a complementary manner. Rail supports of this type facilitate a particularly stable and well adjustable attachment through lateral engagement in the openings of the receiver cavities as will be described infra in more detail.
Alternatively, the C-shaped delimitation of a first or second receiving cavity can also be configured by arms that are at different angles to each other than right angles, or it can be configured arcuate. Also in these cases, at least portions of the C-shaped delimitation can be associated with the typical elements of the letter C in its simplest representation, at least mentally, wherein the simplest representation of the letter C includes two horizontal beams and a vertical beam. In different embodiments of a C-shaped delimitation, it is also feasible that the transitions between respective sections which can be associated with the respective bars of the letter C are continuous.
Defining the opening of the receiver cavities for rail supports can be provided for example through lateral bars.
In one of two alternative embodiments, a single lateral bar is being used. A particularly simple embodiment is facilitated when a lateral bar is arranged on the base plate perpendicular to the base plate. A lateral bar of this type facilitates that a for example U-shaped connection device establishes a form-locking connection therewith and exerts s a force which presses the bottom side of the respective profile rail onto the base formed by the respective trapezoidal sheet. A force of this type can support the profile rail on the base. Furthermore, the form-locking connection can prevent a lateral slide off of the profile rail.
In one variant of the first alternative embodiment, only an upper lateral bar is used for partially closing the receiving cavity for rail supports in laterally outward direction. A receiving cavity thus configured can form a form locking connection with an S-shaped connection device of a rail support and can support the profile rail on the base in this manner and can secure it against slide off and tilting. Preferably the upper lateral bar is arranged perpendicular to the base plate.
Preferably the definition of the opening of the receiving cavity for rail supports is formed in the other of the two alternative embodiments by a lower side bar and by an upper side bar as they were described infra in a context with the variants of the first alternative, wherein the side bars of a respective receiver cavity are respectively arranged orthogonal onto the base plate and are arranged in alignment with one another. This implements an embodiment with a particularly simple configuration which is also particularly compact with respect to its external dimension. Furthermore, stabilization in longitudinal direction is realized through a combination of elements of the profile rail that are oriented perpendicular relative to one another. The embodiment with an upper and a lower transversal bar at the opening of the receiving cavity for rail supports otherwise has the advantage of particular suitability to receive a T-shaped connection device of a rail support and to form a form-locking connection therewith. Thus, a beam of the T-shaped connection device comes into engagement with the lower and also with the upper side bar. This stabilizes the profile rail additionally and thus in particular against tilting.
The respective lateral openings of the receiving cavities of a profile rail according to the first aspect of the invention are oriented in opposite directions. Opposite directions are directions which differ by more than 90°. Particularly preferably they differ by more than 120° and additionally preferably, they differ by approximately or exactly 180°. This facilitates that the openings are configured to insert T-shaped elements of rail supports respectively laterally relative to the profile rail. The direction in which an opening of the receiver cavity is oriented is perpendicular to a surface between the ends of the elements defining it, for example the lateral bars and is oriented away from the receiving cavity with respect to this surface.
According to a particularly preferred embodiment, the second receiving cavity is configured mirror-inverted relative to the first receiving cavity with respect to an imaginary central plane that is perpendicular to the base plate. This facilitates a particularly simple and compact embodiment of the profile rail.
The lateral openings of the first and second receiving cavity do not have to be the only openings of these receiving cavities. Rather, also additional openings, for example for draining rain water, can be provided.
Depending on the arrangement of the third receiving cavity, the configuration of the profile rail in lateral direction can be provided narrower or wider.
The third receiving cavity can be configured between the first and the second receiving cavity for rail supports which facilitates a wider configuration for the profile rail. Alternatively, the third receiving cavity can also be configured above the first and the second receiving cavities. This facilitates a narrower embodiment of the profile rail in which the first and the second receiving cavities can be arranged closely adjacent to one another. By the same token it is also feasible that the third receiving cavity is only configured partially above and partially between the first and the second receiving cavities. This facilitates for example providing stabilizing structures below the third receiving cavity.
The third receiving cavity includes an inner profile which is used for attaching module attaching elements. Module attaching elements are generally defined as elements which are used for establishing a fixed connection between the profile rail and a solar module.
The inner profile can be configured in different ways. For example, two opposite bars can be arranged at the side of the third receiving medium opposite to the base plate, which facilitate that a T-shaped element or a slot nut forms a form-locking connection therewith. An embodiment of this type can correspond to an embodiment of the first or second receiving cavity with an upper and lower side bar as described supra rotated by 90 degrees. The invention, however, is not limited to this embodiment; rather, any inner profile can be used which facilitates attaching components on the profile rail, for example solar modules. Additional preferred embodiments are described infra.
According to a preferred embodiment, the inner profile includes cranks at different walls or bars, wherein the cranks extend substantially parallel to the base plate, wherein a first crank has a greater distance from the base plate than a second crank and wherein the inner profile further includes a first and a second contact surface for an attachment element whose distances to the base plate are smaller than the distance of the first base plate. In an embodiment of this type, it is facilitated through arrangements of the two cranks at a different distance to the base plate that first and second engagement surfaces which are provided in assembled condition for engagement with the first and second crank do not have to be arranged in one plane for an arrangement with one connecting block which shall be used for attaching solar modules on the profile rail. This facilitates particularly simple insertion of the connecting block in the profile rail through slide tilting. The first and the second contact surfaces facilitate that the connecting block remains in place on those two contact surfaces after inserting and that the connecting block is secured against fallout, wedging and rotation. Thus a series of sliding blocks can be inserted into the respective profile rail during assembly before the sliding blocks are subsequently used for attaching solar modules. Since the connecting block shall initially contact the first contact surface and the second contact surface and shall be subsequently pressed upward by an upward oriented force against the two cranks, it is required that the distances of the first and second contact surfaces to the base plate are smaller than at least the distance of the first of the two cranks from the base plate.
Preferably, the first contact surface and the second contact surface are parallel to the base plate. Furthermore, the first contact surface and the second contact surface are arranged at the same distance from the base plate. Applying a connecting block with a flat bottom side is thus facilitated.
According to one embodiment, the first crank and the second contact surface overlap at least partially. According to an additional embodiment, the second crank and the second contact surface overlap at least partially. Those two embodiments can certainly also be combined with one another.
According to a particularly preferred embodiment, the inner profile includes a bar extending from a plane of the base plate, wherein the bar is arranged between two inner walls of the profile rail that are arranged opposite to one another and wherein the bar includes the second crank at its end that is remote from the base plate. Furthermore the first crank is arranged at a first inner wall and is oriented in the same direction as the second crank. Through this embodiment of the inner profile, using a connecting block with U-shape is facilitated. Thus the connecting block can include a first engagement surface which comes into engagement with the first crank under an impact of an upward oriented force and the first connecting block can furthermore include a second engagement surface which comes into engagement under an effect of upward oriented force with the second crank. The second engagement surface of the connecting block is then arranged at a top side of a respective other arm of the U that differs from the arm on which the first engagement surface is arranged.
Preferably, the bar is arranged perpendicular to the base plate. This facilitates a particularly simple embodiment that stabilizes in longitudinal direction.
In a preferred embodiment, the first contact surface extends from the first inner wall. Thus, the first crank and the first contact surface overlap at least partially. The clearance of the connecting block after insertion and before attachment is therefore limited on both sides at the first inner wall.
According to another preferred embodiment, the second contact surface is arranged at an end of the bar that is remote from the base plate. Thus the bar does not only have the function to support the second crank at the desired position, but simultaneously also forms the second contact surface. An additional element for providing the second contact surface can thus be avoided. In particular in this embodiment it is particularly advantageous when the first and second contact surfaces have the same distance from the base plate, thus namely a level and flat application of a connecting block with a flat contact surface is facilitated.
According to an alternative embodiment, the inner profile is configured so that a simple slot nut can be inserted and attached. According to another alternative embodiment, the inner profile is configured so that a hexagonal nut can be laterally inserted and attached.
A second aspect of the invention relates to an attachment system for mounting solar modules on a trapezoidal sheet which includes raised beads and associated flanks including at least one profile rail according to the first aspect of the invention and a plurality of rail supports respectively including the following:

- a main element,
- a first clearance hole in the main element, and
- a T-shaped component extending from the main element,

wherein the profile rail is attachable at the raised beads via the rail supports, wherein the T-shaped components engage the lateral openings respectively of the first or the second receiving cavity with attachment of the rail supports at the flanks via attachment devices through the clearance holes,
wherein the top sides of the main elements of the rail supports do not protrude beyond a top side of the profile rail in assembled condition.
An attachment system of this type includes an inventive combination of a profile rail with associated rail supports. The supports can be easily brought into a form locking connection with the profile rail through the T-shaped component extending from the main element. Thus the T-shaped component is either inserted into the first or into the second receiving cavity for the rail support of the profile rail and rotated in a suitable manner. Furthermore, the supports can be attached through their respective clearance holes at a respective flank of a trapezoidal sheet. Thus the main element which is freely movable in longitudinal direction and which can still be rotated further after insertion of the T-shaped component into one of the two lateral openings of the profile rail and after rotating the T-shaped component in the respective first or second receiving cavity for rail supports is preferably placed flat onto a flank of the trapezoidal sheet. For attachment purposes, typical elements like screws or rivets are suitable which are inserted through the clearance hole and driven into the material of the trapezoidal sheet. Thus a fixated and non-movable connection between the support and the trapezoidal sheet can be configured. Thus as described supra, the profile rail can be fixated on the trapezoidal sheet and secured against sliding off or tilting through a fixated connection of this type through form locking connection of the support at the profile rail.
It is appreciated that the top sides of the rail supports of the attachment system do not extend according to the invention in assembled condition beyond a top side of the profile rail. This facilitates lateral assembly of the rail supports at the profile rail and flat placement of a solar module on the profile rail.
A third aspect of the invention relates to an arrangement for attaching solar modules with an attaching system according to the second aspect and a trapezoidal sheet which includes raised beads and associated flanks,

- wherein the profile rail rests on the raised beads,
- wherein the rail supports are attached with attachment devices through their clearance holes at the flanks of the raised beads of the trapezoidal sheet, and
- wherein the T-shaped components of the rail supports either engage the lateral opening of the first or the second receiving cavity of the profile rail.

The arrangement according to the third aspect of the invention thus relates to a combination of a trapezoidal sheet with an attachment system according to the second aspect in assembled condition. As described already in conjunction with the attachment system, the main elements of the rail supports preferably rests plane on the respective flanks of the trapezoidal sheet in contact surfaces and form a form locking connection with the profile rail through their T-shaped components. Thus the rail supports are arranged on sides of the profile rail. Thus the profile rail is fixated on the raised beads of the trapezoidal sheet. Thus the trapezoidal sheet and the profile rail form a permanently connected unit.
Preferably flat spacers are installed between the trapezoidal sheet and the profile rail. These spacers can be produced for example from ethylene propylene diene monomer rubber (EPDM) which has properties that are advantageous for this type of application. The spacers help to prevent contact corrosion between the materials.
As already indicated, in conjunction with the profile rail according to the invention, the arrangement according to this aspect of the invention is characterized in that rather large forces can be introduced into the trapezoidal sheet and thus higher loads can be sustained (shear loading). The support of the profile rail according to the invention facilitates tolerance relative to temperature based length changes of the materials.
When mounting the supports, the arrangement according to the invention facilitates particularly high flexibility. The number of the supports can be reduced further based on the static loads. The supports can be mounted at the flanks of each raised bead but they can for example also be mounted at every second or third raised bead. Thus not only the loading of the trapezoidal sheet can be optimized as recited supra.
According to one embodiment of the arrangement, the rail supports of a respective profile rail are accordingly only mounted on one side of the profile rail. This means that either in the first or the second receiving cavity for the rail support, no rail support is attached. Based on the configuration of the receiving cavity and of the rail supports, this can suffice in principle for safe assembly of the profile rail.
Preferably, however, the rail supports are mounted on both sides of the profile rail, so that a respective support effect occurs on both sides of the profile rail. This yields a particularly advantageous distribution of the forces impacting the trapezoidal sheet.
The rail supports can be mounted so that a compressive load and a tensile load are exerted on the trapezoidal sheet in an alternating manner. Thus the rail supports have to be supported contacting an upper or lower delimitation of the receiving cavity during assembly in case their respective T-shaped component has a clearance in the respective receiving cavity before the T-shaped component is attached at the respective flank through an attachment device. In case the trapezoidal sheet has a height difference, a respective rail support can be still attached at each flank.
It is not required as a matter of principle that rail supports are attached at each flank. Rail supports can for example be attached at every second, third, fourth, etc. flank. By the same token, rail supports can be alternatively arranged on the respective sides of the profile rail.
In addition to the rail supports, upper trapeze supports can be mounted at the raised beads, wherein the upper trapeze supports additionally hold the profile rail. The upper trapeze supports can be advantageously used for example under high suction load or with insufficient raised bead height of the trapezoidal sheets. Upper trapeze supports of this type include for example a contact plate with a clearance hole through which they can be attached at a raised bead. Furthermore, the upper trapeze supports for example include a C-shaped support element which engages the receiving cavity of the profile rail. Thus an additional support of the profile rail can be facilitated.
A fourth aspect of the invention relates to a method for mounting an attachment system according to the second aspect on a trapezoidal sheet which includes raised beads and associated flanks, the method including the following steps:
a) placing the profile rail with its bottom side on raised beads of the trapezoidal sheet;
b) inserting the T-shaped element of one of the rail supports into one of the receiving cavities of the profile rail;
c) attaching the rail support at one of the flanks with an attachment device which extends through a clearance hole of the rail support;
d) repeating of steps b) and c) at least once with respectively one further rail support.
The method according to the fourth aspect of the invention facilitates a simple assembly of a profile rail from the attachment system according to the second aspect with the associated rail supports. The rail supports can thus be mounted on one side or preferably on both sides of the profile rail.
The method according to the fourth aspect of the invention facilitates transferring the attachment system according to the second aspect and a trapezoidal sheet into the arrangement according to the third aspect of the invention. The already recited variants and advantages also apply analogously for the method according to the fourth aspect of the invention.
Since the profile rail is loosely applied to the flat roof at the beginning of the method and not till then respective rail supports are attached at suitable flanks, the method according to the fourth aspect of the invention has a maximum amount of flexibility. Exactly the required amount of rail supports can be mounted for a particular profile rail and their positions are largely selectable at will. Through the lateral assembly of the supports, the locations where method steps have to be performed are easily accessible.
In order to secure a position, this means preventing the supports from sliding out, a screw with a nut fitting into the receiving cavity can be attached at rail ends directly adjacent to the last supports. Thus the rail can move freely during temperature expansions, but cannot slide out.
Through the profile rail according to the invention, the attachment system, the arrangement and the method, solar modules can be attached at continuous rails at certain points and also in rows.

Additional features and advantages of the invention can be derived from the subsequent descriptions of embodiments with reference to following figures, wherein:

FIG. 1 illustrates a first embodiment of a profile rail according to the first aspect of the invention;

FIG. 2 illustrates a second embodiment of a profile rail according to the first aspect of the invention;

FIG. 3 illustrates the profile rail of FIG. 2 with a connecting block inserted;

FIG. 4 illustrates a rail support for an attachment system according to the second aspect of the invention;

FIG. 5 illustrates a profile rail and a rail support;

FIG. 6 illustrates an attachment system according to the second aspect of the invention;

FIG. 7 illustrates an arrangement according to the third aspect of the invention;

FIG. 8 illustrates a flow diagram of a method according to the fourth aspect of the invention.

FIG. 1 illustrates a cross-sectional view of a first embodiment of a profile rail 1000 according to the first aspect of the invention. The profile rail includes a base plate 1100 whose bottom side forms a bottom side 1110 of the profile rail. The bottom side 1110 includes a notch 1120 so that the bottom side 1110 is only planar in sections. The bottom side 1110 as long as it is flat forms a contact surface of the profile rail on which the profile rail rests in assembled condition.
Above the base plate 1100, the profile rail includes a first receiving cavity 1200 for rail supports which is partially closed towards the left side in FIG. 1. For this purpose, lateral bars 1220, 1230 are being used between which a lateral opening 1210 is formed. Besides the opening 2010 and the two lateral bars 1220, 1230, the first receiving cavity 1200 is defined C-shaped. This is achieved by two horizontal arms 1240, 1260 and a vertical arm 1250, wherein the two horizontal arms 1240, 1260 correspond to the horizontal C-bars, wherein the vertical arm 1250 corresponds to a vertical C-bar.
A second receiving cavity 1300 for rail supports is arranged mirror-inverted to the first receiving cavity 1200 for rail supports, wherein the second receiving cavity is partially closed towards a right side of FIG. 1 through two lateral bars 1320, 1330. Like for the first receiving cavity 1200, a lateral opening 1310 is formed between the lateral bars 1320, 1330 of the second receiving cavity 1300. Also the second receiving cavity 1300 is defined C-shaped through two horizontal arms 1340, 1360 and a vertical arm 1350.
Additionally, the profile rail 1000 includes a third receiving cavity 1400 which is also arranged above the base plate 1100 and also above the first and the second receiving cavity 1200, 1300. The third receiving cavity 1400 includes an inner profile 1500 which is formed from two horizontal bars 1510, 1520. Between the two horizontal bars 1510, 1520 which have identical distances from the base plate 1100, an opening 1410 is configured that is oriented away from the bottom side 1110 of the profile rail. As apparent in FIG. 1, the opening 1410 is oriented in upward direction when the profile rail rests with its bottom side 1110.
The first and the second receiving cavity 1200, 1300 for rail supports are used for receiving suitable connection devices of rail supports in order to mount the profile rail 1000 on a trapezoidal sheet, wherein in particular T-shaped and U-shaped connection devices are suitable. Thus a form-locking connection between the profile rail 1000 and the respective rail support can be established. When the rail support is subsequently connected with the trapezoidal sheet, a form-locking connection is also created between the profile rail 1000 and the trapezoidal sheet, with which the profile rail 1000 on the trapezoidal sheet.
In the third receiving cavity 1400, suitable connection devices of module attachment elements or also complete module attachment elements can be received. The delimitation recited supra of the third receiving cavity 1400 through the horizontal bars 1510, 1520 facilitates a form-locking connection between the module attachment element and the profile rail 1000 when the connection devices are configured in a suitable manner. In turn a solar module, for example a photovoltaic module or a solar collector module can be attached at the module attachment element, wherein the solar module is mounted on the trapezoidal sheet in this manner.
FIG. 2 illustrates a second embodiment of a profile rail 2000 according to the first aspect of the invention. The profile rail 2000 includes a base plate 2100 which forms a completely flat bottom side 2110 of the profile rail. Laterally with respect to the profile rail, similar to the profile rail 1000 illustrated in FIG. 1, a first and a second receiving cavity 2200, 2300 for rail supports are configured. They are respectively defined in outward direction through lateral bars 2220, 2230 and 2320, 2330 between which respective lateral openings 2210, 2310 are configured. Also the first and the second receiving cavity 2200, 2300 for rail supports are respectively delimited C-shaped besides the lateral bars 2220, 2230, 2320, 2330 and the openings 2200, 2300.
The profile rail 2000 furthermore includes a third receiving cavity 2400 which forms an opening 2410 that is oriented away from a bottom side 2110 of the profile rail. The third receiving cavity 2400 is laterally defined through a first inner wall 2420 and a second inner wall 2430 and defined in downward direction by the base plate 2100.
An inner profile 2500 is configured in the third receiving cavity 2400, wherein the inner profile includes a first crank 2510, a first contact surface 2530 and a bar 2550 with a second crank 2520 and a second contact surface 2540. The first crank 2510 and the first contact surface 2530 both protrude from the first inner wall 2420. The first crank 2510 is thus further remote from the base plate 2100 than the first contact surface 2530. Furthermore, the first contact surface 2530 protrudes further into the third receiving cavity 2400 than the first crank 2510. At an end of the bar 2550 that is remote from the base plate 2100, the crank 2520 and the second contact surface 2540 are arranged. The second crank 2520 is oriented away from the first inner wall 2420 like the first crank 2510. The second contact surface 2540 has the same distance from the base plate 2100 as the first contact surface 2530. The bar 2550 extends perpendicular to the base plate 2100.
The functions of the bottom side 2110 and of the first and second receiving cavities 2200, 2300 for rail supports are identical to those of the bottom side 1110 and the first and second receiving cavity 1200, 1300 for rail supports of the profile rail 1000 which is illustrated in FIG. 1. Therefore, a repeated description is omitted.
The inner profile 2500 facilitates forming a form locking connection with suitable connecting blocks. Details are subsequently described with reference to FIG. 3.
FIG. 3 illustrates the profile rail 2000 of FIG. 2 with an inserted connecting block 3000. The connecting block 3000 includes a contact surface 3100 and is configured U-shaped on one side. Thus the connecting block includes a first engagement surface 3300 at its top side and a second engagement surface 3400 at a top side of a lower arm of the U. A borehole 3200 extends through the connecting block 3000 which facilitates connecting the connecting block through a threaded bolt with an element above the profile rail. An element of this type can be for example another profile rail, a solar module like a photovoltaic module or a solar collector module or also a spacer.
In order to mount the connecting block 3000, it is initially placed with its contact surface 3100 onto the first contact surface 2530 and the second contact surface 2540 of the profile rail 2000. This facilitates inserting plural connecting blocks after the profile rail is mounted on a trapezoidal sheet, wherein wedging, pivoting or falling out of the connecting blocks can be excluded. When an upward directed force is exerted upon the connecting block 3000 through a bolt inserted into the borehole 3200, the connecting block is pulled upward and away from the base plate 2100. Thus the first engagement surface 3300 comes into engagement with the first crank 2510; furthermore the second engagement surface 3400 also comes into engagement with the second crank 2520. Thus the connecting block 3000 seizes with the profile rail 2000 so that an attachment of the element that is arranged above the profile rail 2000 is facilitated through the form locking connection. Overall, the combination of the connecting block 3000 with the profile rail 2000 facilitates a particularly simple assembly of the elements arranged above the profile rail 2000.
FIG. 4 illustrates a rail support 4000 for an attachment system according to the second aspect of the invention. The rail support 4000 includes a main element 4100 which has an elongated shape. Proximal to one end, there is a T-shaped component which includes a bar 4220 and an extension 4210. The bar 4220 is thus configured parallel to the main element 4100 and connected with the main element through the extension 4210. The main element 4100 furthermore includes a protrusion 4300 in which two clearance holes 4310, 4320 are configured. In a direction perpendicular to the plane illustrated in FIG. 4, the rail support 4000 has a constant thickness.
The T-shaped component 4200 when mounting a profile rail 1000, 2000 according to the first aspect of the invention is used for forming a form-locking connection with one of the receiving cavities 1200, 1300, 2200, 2300 of the respective profile rail. For this purpose, the bar 4220 of the T-shaped component 4200 has to be placed initially substantially parallel to the longitudinal extension of the respective opening 1210, 1310, 2210, 2310. Subsequently, the bar is inserted through the opening into the respective receiving cavity. After insertion, the support 4000 is rotated about the extension 4210. This establishes a form-locking connection between the support 4100 and the profile rail 1000, 2000 so that the support 4000 cannot be removed anymore without turning the profile rail back. In order to mount the respective profile rail on a trapezoidal sheet, the rotation is performed so that the main element 4100 essentially contacts a flank of a vertical support fin flatly. Subsequently, suitable attachment devices, for example bolts or rivets, are inserted through one or both clearance holes 4310, 4320 and driven into the material of the trapezoidal sheet. When this is performed so that a tight non-moving connection between the support 4000 and the trapezoidal sheet is formed, also the profile rail is supported on the trapezoidal sheet through the support 4000.
FIG. 5 illustrates a profile rail 1000 according to the first embodiment as illustrated in FIG. 1 with an inserted and rotated rail support 4000. It is evident that the bar 4220 of the T-shaped component 4200 of the rail support 4000 which is inserted in the second receiving cavity 1300 of the profile rail 1000 forms a form locking connection with the vertical arm 1350 and the side arms 1320, 1330. It is furthermore apparent that the bar 4220 has clearance in upward direction in the second receiving cavity 1300. This facilitates a compensation of unevenness and tolerance relative to temperature induced length changes of the components used. It is apparent from the described form locking connection that eventually also the profile rail 1000 is attached through attaching the rail support 4000 at a flank of the trapezoidal sheet.
FIG. 6 illustrates an embodiment of an attachment system according to the third embodiment of the invention. The attachment system includes two profile rails 2000 according to the second embodiment and twelve rail supports 4000. With respect to the configuration of the profile rails 2000, reference is made to FIG. 2. With respect to the configuration of the rail supports 4000, reference is made to FIG. 4.
The attachment system of FIG. 6 facilitates parallel mounting of two profile rails on a trapezoidal sheet. Each of the two profile rails 2000 can thus be attached at the trapezoidal sheet with six rail supports 4000. A parallel assembly of two profile rails is typically used to mount a series of solar modules. Each module contacts each of the two profile rails. The solar modules are attached at the profile rails with suitable module attachment elements which come into engagement with the inner profiles 1500, 2500 of the profile rails.
However, it is appreciated that attachment systems according to the invention are not limited to a number of two profile rails and twelve rail supports. Rather, any other useful combination of profile rails and supports can be used and can be considered for example as a kit for mounting solar modules.
FIG. 7 illustrates an arrangement 7000 for attaching solar modules with an attachment system according to the second aspect of the invention and with a trapezoidal sheet 7500.
The trapezoidal sheet 7500 includes beads 7510 and raised beads 7540 arranged there between. Two flanks 7520, 7530 are associated with each raised bead, wherein the flanks connect respectively adjacent beads 7510 and raised beads 7540. The beads 7510, flanks 7520, 7530 and the raised beads 7540 are bent from a single continuous metal plate.
The profile rail 2000 contacts the raised beads 7540 of the trapezoidal sheet 2500 with its bottom side 2110. On both sides of the profile rail respective supports 4000 are applied thus so that their respective T-shaped components form a form-locking connection with the delimitations of the first and second receiving cavities 2200, 2300. Furthermore, the supports 4000 are attached with screws 7100 at respective flanks 7520, 7530. Through forming a connection of the attachment on the profile rail already described with reference to FIG. 5, also the profile rail 2000 is supported on the trapezoidal sheet 7500. Mounting the rail supports 4000 on both sides facilitates additional stabilization of the profile rail on the raised beads.
FIG. 8 illustrates a method for mounting an attachment system according to the second aspect of the invention on a trapezoidal sheet. As illustrated in FIG. 7 the trapezoidal sheet includes raised beads and associated flanks.
Initially a first profile rail from the attachment system is placed in a step S81 with its bottom side on raised beads of the trapezoidal sheet. Subsequently the T-shaped portion of one of the rail supports out of the attachment system is inserted in a step S82 into one of the receiving cavities of the profile rail. The rail support is subsequently turned in step S83 so that its main element contacts one of the flanks and the rail support is attached at the flank through a screw. Steps S82 of inserting and S83 of attaching the rail supports are repeated several times in step S84 until a sufficient number of rail supports is mounted in order to fixate the profile rail on the raised beads.
Subsequently, a second profile rail from the attachment system is applied parallel to the first profile rail in step S85. The second profile rail has to be offset from the first profile rail so that applying and attaching modules is feasible.
The steps S82 through S84 are subsequently also repeated for the second profile rail until the second profile rail is mounted on the trapezoidal sheet with sufficient strength.
Thus it is not necessary that the second profile rail is attached at the same flanks as the first profile rail. Rather, both profile rails can be attached independently from one another as required by boundary conditions like for example compensating unevenness, providing expansion tolerance or presence of obstacles on the trapezoidal sheet.

Claims

1. A profile rail comprising in a cross-sectional view:

a base plate which forms a bottom side of the profile rail and which is flat in sections or completely flat;

a first and a second receiving cavity for rail supports which are both partially closed laterally in an outward direction and which respectively include a lateral opening, wherein the two lateral openings are oriented in opposite directions; and

a third receiving cavity which includes an opening that is oriented away from the bottom side of the profile rail and which includes an inner profile for attaching module attachment elements.

2. The profile rail according to claim 1, wherein the first or the second receiving cavity is internally defined by a C-shape.

3. The profile rail according to claim 1, wherein the first receiving cavity or the second receiving cavity is laterally closed partially in outward direction by at least one lateral bar arranged orthogonal to the base plate.

4. The profile rail according to claim 1, wherein the second receiving cavity is mirror symmetrical to the first receiving cavity with respect to an imaginary center plane which is orthogonal to the base plate.

5. The profile rail according to claim 1,

wherein the inner profile includes cranks at different walls or bars,

wherein the cranks extend substantially parallel to the base plate,

wherein a first crank has a greater distance from the base plate than a second crank, and

wherein the inner profile further includes a first and a second contact surface for an attachment element whose distances from the base plate are smaller than a distance of the first crank from the base plate.

6. The profile rail according to claim 1, wherein the first contact surface and the second contact surface are parallel to the base plate.

7. The profile rail according to claim 5,

wherein the first crank and the first contact surface overlap at least partially, or

wherein the second crank and the second contact surface overlap at least partially.

8. The profile rail according to claim 5,

wherein the inner profile includes a bar that protrudes from a plane of the base plate,

wherein the bar is arranged between two inner walls of the profile rail that are arranged opposite to one another,

wherein the bar has a second crank at its end that is remote from the base plate, and

wherein the first crank is arranged at a first inner wall and oriented in the same direction as the second crank.

9. The profile rail according to claim 8, wherein the bar is orthogonal to the base plate.

10. The profile rail according to claim 8, wherein the first contact surface protrudes from the first inner wall.

11. The profile rail according to claim 8, wherein the second contact surface is arranged at the end of the bar that is remote from the base plate.

12. An attachment system for mounting solar modules on a trapezoidal sheet which includes raised beads and associated flanks, comprising

at least one profile rail according to claim 1; and

a plurality of rail supports respectively including

a main element,

a first clearance hole through the main element, and

a T-shaped component extending from the main element,

wherein the profile rail is attachable at the raised beads via the rail supports,

wherein the T-shaped components engage the lateral openings respectively of the first or the second receiving cavity and with attachment of the rail supports at the flanks via attachment devices through clearance holes,

wherein the top sides of the main elements of the rail supports do not protrude beyond a top side of the profile rail in assembled condition.

13. An arrangement for attaching solar modules with an attaching system according to claim 12 and a trapezoidal sheet which includes raised beads and associated flanks,

wherein the profile rail rests on the raised beads,

wherein the rail supports are attached with attachment devices through their clearance holes at the flanks of the raised beads of the trapezoidal sheet, and

wherein the T-shaped components of the rail supports either engage a respective lateral opening of the first or the second receiving cavity of the profile rail.

14. A method for mounting an attachment system according to claim 12 on a trapezoidal sheet which includes raised beads and associated flanks, the method comprising the steps:

a) placing the profile rail with its bottom side on raised beads of the trapezoidal sheet;

b) inserting the T-shaped element of one of the rail supports into one of the receiving cavities of the profile rail;

c) attaching the rail support at one of the flanks with an attachment device which extends through a clearance hole of the rail support;

d) repeating steps b) and c) at least once with respectively one further rail support.

15. A method according to claim 14, wherein the rail supports are mounted on both sides of the profile rail.