WO2010133242A1 - Mounting system for solar panels and connecting bracket for same - Google Patents

Mounting system for solar panels and connecting bracket for same Download PDF

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Publication number
WO2010133242A1
WO2010133242A1 PCT/EP2009/003616 EP2009003616W WO2010133242A1 WO 2010133242 A1 WO2010133242 A1 WO 2010133242A1 EP 2009003616 W EP2009003616 W EP 2009003616W WO 2010133242 A1 WO2010133242 A1 WO 2010133242A1
Authority
WO
WIPO (PCT)
Prior art keywords
mounting
elongate
longitudinal axis
mounting system
solar panels
Prior art date
Application number
PCT/EP2009/003616
Other languages
French (fr)
Inventor
Geerling Loois
Stephan Zschoch
Jan Wenzlaff
Michael Kübsch
Original Assignee
Renusol Gmbh
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Renusol Gmbh filed Critical Renusol Gmbh
Priority to PCT/EP2009/003616 priority Critical patent/WO2010133242A1/en
Publication of WO2010133242A1 publication Critical patent/WO2010133242A1/en

Links

Classifications

    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F24—HEATING; RANGES; VENTILATING
    • F24S—SOLAR HEAT COLLECTORS; SOLAR HEAT SYSTEMS
    • F24S25/00—Arrangement of stationary mountings or supports for solar heat collector modules
    • F24S25/60—Fixation means, e.g. fasteners, specially adapted for supporting solar heat collector modules
    • F24S25/63—Fixation means, e.g. fasteners, specially adapted for supporting solar heat collector modules for fixing modules or their peripheral frames to supporting elements
    • F24S25/634—Clamps; Clips
    • F24S25/636—Clamps; Clips clamping by screw-threaded elements
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F24—HEATING; RANGES; VENTILATING
    • F24S—SOLAR HEAT COLLECTORS; SOLAR HEAT SYSTEMS
    • F24S20/00—Solar heat collectors specially adapted for particular uses or environments
    • F24S20/60—Solar heat collectors integrated in fixed constructions, e.g. in buildings
    • F24S20/67—Solar heat collectors integrated in fixed constructions, e.g. in buildings in the form of roof constructions
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F24—HEATING; RANGES; VENTILATING
    • F24S—SOLAR HEAT COLLECTORS; SOLAR HEAT SYSTEMS
    • F24S25/00—Arrangement of stationary mountings or supports for solar heat collector modules
    • F24S25/30—Arrangement of stationary mountings or supports for solar heat collector modules using elongate rigid mounting elements extending substantially along the supporting surface, e.g. for covering buildings with solar heat collectors
    • F24S25/33—Arrangement of stationary mountings or supports for solar heat collector modules using elongate rigid mounting elements extending substantially along the supporting surface, e.g. for covering buildings with solar heat collectors forming substantially planar assemblies, e.g. of coplanar or stacked profiles
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F24—HEATING; RANGES; VENTILATING
    • F24S—SOLAR HEAT COLLECTORS; SOLAR HEAT SYSTEMS
    • F24S25/00—Arrangement of stationary mountings or supports for solar heat collector modules
    • F24S25/60—Fixation means, e.g. fasteners, specially adapted for supporting solar heat collector modules
    • F24S25/61—Fixation means, e.g. fasteners, specially adapted for supporting solar heat collector modules for fixing to the ground or to building structures
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F24—HEATING; RANGES; VENTILATING
    • F24S—SOLAR HEAT COLLECTORS; SOLAR HEAT SYSTEMS
    • F24S25/00—Arrangement of stationary mountings or supports for solar heat collector modules
    • F24S25/60—Fixation means, e.g. fasteners, specially adapted for supporting solar heat collector modules
    • F24S25/61—Fixation means, e.g. fasteners, specially adapted for supporting solar heat collector modules for fixing to the ground or to building structures
    • F24S25/615—Fixation means, e.g. fasteners, specially adapted for supporting solar heat collector modules for fixing to the ground or to building structures for fixing to protruding parts of buildings, e.g. to corrugations or to standing seams
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F24—HEATING; RANGES; VENTILATING
    • F24S—SOLAR HEAT COLLECTORS; SOLAR HEAT SYSTEMS
    • F24S25/00—Arrangement of stationary mountings or supports for solar heat collector modules
    • F24S25/60—Fixation means, e.g. fasteners, specially adapted for supporting solar heat collector modules
    • F24S25/65—Fixation means, e.g. fasteners, specially adapted for supporting solar heat collector modules for coupling adjacent supporting elements, e.g. for connecting profiles together
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F24—HEATING; RANGES; VENTILATING
    • F24S—SOLAR HEAT COLLECTORS; SOLAR HEAT SYSTEMS
    • F24S25/00—Arrangement of stationary mountings or supports for solar heat collector modules
    • F24S2025/80—Special profiles
    • F24S2025/801—Special profiles having hollow parts with closed cross-section
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02B—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO BUILDINGS, e.g. HOUSING, HOUSE APPLIANCES OR RELATED END-USER APPLICATIONS
    • Y02B10/00—Integration of renewable energy sources in buildings
    • Y02B10/20—Solar thermal
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
    • Y02E10/00—Energy generation through renewable energy sources
    • Y02E10/40—Solar thermal energy, e.g. solar towers
    • Y02E10/47—Mountings or tracking

Definitions

  • first portion and the second portion of the respective mounting member may have substantially the same configuration in cross-section, i.e. the same configuration perpendicular to their respective longitudinal axes.
  • the second portion forms an end portion of the respective mounting member.
  • the second portion may, for example, be arranged below the first portion in the respective mounting member.
  • connection means comprises a bracket member adapted to engage with a side region of the first portion and/or a side region of the second portion of the respective mounting member.
  • the bracket member may comprise one or more connecting elements for engagement with the side regions of the first portion and the second portion of the respective mounting member.
  • connection means may additionally include an engagement structure formed in the side region(s) of the first portion and/or the second portion of the respective mounting member, with the engagement structure preferably including one or more recess for receiving and engaging the one or more connecting elements of the bracket member.
  • the one or more connecting elements of the bracket member may, for example, comprise a projecting profile adapted to complement the recess formed in the side region(s) of the first portion and/or the second portion of the respective mounting member.
  • the mounting system further comprises a roof cladding material adapted to be attached to and supported by the elongate mounting members.
  • the cladding material is adapted to be arranged between the mounting members and the one or more solar panels.
  • An upper surface of the elongate mounting members thus preferably bears against an underside of the roof cladding material.
  • the roof cladding material may, for example, comprise a sheet material having one or more corrugations or channels formed therein.
  • the sheet material is preferably designed to be supported such that the mounting members are arranged to extend within the corrugations or channels formed in the sheet material.
  • the sheet material is desirably formed from a polymer plastics material and is both impervious to water and weather resistant.
  • the sheet material may optionally comprise a plurality of individual panels adapted to be arranged overlapping one another, the panels typically being of a rigid or semi-rigid construction.
  • each fastening arrangement comprises a clamping member for securely attaching the roof cladding material to the respective mounting member.
  • the fastening arrangement preferably comprises a clip device for securely attaching the one or more solar panels to the mounting member, with the clip device being designed to be provided on or carried by the clamping member.
  • the clamping member may be elongate, preferably formed as a rail element, and is preferably designed to extend longitudinally of the mounting member. As such, the position of the clip device may be adjustable along the length of the elongate, rail-like clamping member.
  • the clamping member may also present a seating surface on an upper side thereof for receiving and supporting a solar panel.
  • the present invention provides a bracket member for interconnecting an elongate first portion and an elongate second portion of a mounting member in a mounting system for mounting one or more solar panels.
  • the bracket member is adapted to interconnect the first portion and the second portion of the respective mounting member such that a longitudinal axis of the second portion is displaced or offset relative to (i.e. not coaxial with) a longitudinal axis of the first portion.
  • the bracket member comprises one or more connecting elements for engagement with the first portion and the second portion of the mounting member when the first portion and the second portion are positioned in alignment with one another.
  • the connecting elements of the bracket member are adapted for engagement with the first portion and/or the second portion of the mounting member such that the second portion is arranged to partially overlap with the first portion in a longitudinal direction. That is, the first portion and the second portion are preferably connected such that they extending next to, and in parallel with, one another.
  • the bracket member may comprise an aperture which accommodates a connecting element, such as a bolt, adapted to be received in and to engage with a respective complementary recess in a side region of the first or second portion of the mounting member.
  • the connecting element e.g. bolt, may in this case be detachable from the bracket member.
  • each of the mounting members comprises an elongate first portion with a first longitudinal axis, and an elongate second portion with a second longitudinal axis.
  • the mounting system further comprises connection means adapted to connect the first portion and the second portion of a respective mounting member such that the second longitudinal axis is displaced or offset relative to the first longitudinal axis.
  • the mounting system includes at least one and preferably a plurality of solar panels for assembly with the mounting members in a solar panel array.
  • the invention also provides a method of mounting one or more solar panels, comprising the steps of: arranging an elongate first portion of an elongate mounting member for supporting one or more solar panels thereon on or across beams of a supporting structure, such as a roof framework; arranging an elongate second portion of the elongate mounting member adjacent to and in general alignment with, but axially offset from, the first portion; and securely interconnecting the first portion and the second portion of the mounting member - i.e. such that a longitudinal axis of the second portion is displaced or offset relative to a longitudinal axis of the first portion.
  • the elongate first portion of the mounting member is fixed or secured to the supporting structure before the second portion of that mounting member is interconnected with the first portion.
  • a plurality of elongate mounting members each of which has an elongate first portion and an elongate second portion, are fixed or secured on the supporting structure such that a longitudinal axis of each second portion is displaced or offset relative to a longitudinal axis of each respective first portion. Furthermore, the mounting members are arranged and secured substantially parallel and laterally spaced apart from one another for supporting one or more solar panels thereon.
  • Fig. 1 is a perspective view of a mounting system for solar panels according to a preferred embodiment of the invention shown assembled with the solar panels on part of a rooftop;
  • Fig. 4 is a perspective view in the direction marked "View A" in Fig. 3 of the end portion of the mounting member and its attachment to a side face of a beam of the roof structure;
  • Fig. 12 is a cross-sectional view of the mounting system and rooftop shown in Fig. 1 taken in the direction of the arrows XIl-XII;
  • a mounting system 100 is illustrated in an assembled state installed on a rooftop R.
  • the mounting system 100 shown in Fig. 1 has been designed to carry ten rectangular solar panels S securely fixed to a mounting frame 10 of the mounting system in a rectangular array. Seven of the solar panels S are shown mounted on the mounting frame 10 and three are absent to reveal parts of the underlying mounting system 100, which will be described in more detail with reference to the following drawings.
  • the solar panels S in this embodiment comprise glass photovoltaic panels or modules and typically have a metal frame or rim (e.g. of aluminium) extending around their outer periphery, which facilitates the fastening of the solar panels S to the mounting frame 10.
  • the solar panels S are usually rectangular and typically present a collecting surface with an area in the range of about 0.5 m 2 to about 4 m 2 , though the area and the dimensions of the panels are not critical to the present invention.
  • the mounting frame 10 of the mounting system 100 comprises a plurality of elongate mounting members 20, which in this particular embodiment are made up of individual straight elements having a substantially uniform or constant cross- section, and which are formed, for example, as extruded aluminium sections.
  • the mounting members 20 are elongate structural elements 21 upon which the solar panels are mounted and supported within the frame 10 of the mounting system 100.
  • the mounting members 20 will hereafter also be referred to as mounting "rails", as they are often known in the art.
  • FIG. 2 An angled or pitched roof is not essential for the mounting system 100 of the invention, but is often encountered in practice.
  • the cross-section of Fig. 2 is shown in a horizontal orientation (i.e. without the roof pitch) but, in practice, the rooftop R is angled to slope downwardly from right to left in this case.
  • the horizontal representation of Fig. 2 is useful because it helps illustrate that the upper surfaces of the roof beams B together form seating surfaces which generally lie within a common plane, and these surfaces ordinarily support the sheet material of roof cladding C. As this cladding C has been partially removed for the installation of the solar panel array, however, a large section of these beam surfaces are now free for the support and attachment of the mounting rails 20 in the mounting system 100.
  • each of the mounting rails 20 in this embodiment includes a plurality of elongate elements or sections 21 which are interconnected with one another. Further, each of these elements or sections 21 which are combined to form the mounting rail 20 has the same cross-sectional configuration. An individual one of these elements or sections 21 is illustrated in Fig. 8 and Fig. 9 of the drawings.
  • the element or section 21 has a generally rectangular cross-section and includes a central cavity 22 which extends along the length of thereof.
  • two flange-like footings 23 are provided which also extend along the length of the element and present planar surfaces upon which the element 21 may be stably supported.
  • a plain surface 24 is provided which, as will be seen later, may form a bearing surface for supporting roof cladding material.
  • Lateral side regions 25 of the elongate element 21 include upper and lower projections 26, 27, which together partially encompass a recess 28 formed in each side region 25. Each recess 28 extends along the respective side region 25 in the form of a channel.
  • the upper and lower projections 26, 27 are shaped as right-angled sections and include oppositely extending upper and lower flange elements 29, 30 which define a gap there-between opening into the recess or channel 28 at the sides 25 of the elongated element 21.
  • the mounting rail 20 can be seen to comprise an elongate first portion 31 and an elongate second portion 32, and each of these first and second portions 31 , 32 comprises at least one elongate element 21 as shown in Fig. 8 and Fig. 9.
  • the elongate second portion 32 is offset or displaced with respect to the first portion 31 so that it is not coaxial with the first portion 21.
  • the second portion 32 forms an end portion of the mounting rail 20 and, although it partially overlaps with the first portion 31 in a region 33, it extends below the first portion 31.
  • a central longitudinal axis X 32 of the second portion 32 is displaced or offset a distance d in a downward direction from a central longitudinal axis X 31 of the first portion 31.
  • This offset or displaced configuration at the end portion of the mounting rail 20 in the region denoted "Z" in Fig. 2 is the same at the opposite end portion of the mounting rail 20, as can be seen.
  • the axially offset or displaced configuration of the mounting rail 20 is effected via a connector means in the form of a bracket member 40. That is, the connector means or bracket member 40 is adapted for interconnecting the elongate first and second portions 31 , 32 of the mounting rail 20, such that the first portion 31 and the second portion 32 extend in the offset or displaced configuration shown in Fig. 3. For this reason, the bracket member 40 is also referred to herein as a connecting bracket.
  • the specific configuration of the connecting bracket 40 in this embodiment of the invention is shown in detail in Figs. 10 and 11 of the drawings.
  • the bracket 40 is typically fabricated as an integral component from a rigid and robust material, such as aluminium or steel or another metal.
  • the bracket 40 comprises a body part 41 formed from plate material and is substantially flat and rectangular.
  • the bracket 40 comprises connecting elements provided on the body part 41 for engagement with both the first and second portions 31 , 32 of the mounting rail 20 when these are brought into position adjacent one another.
  • the connecting elements at a lower region of the bracket 40 comprise a pair of projecting elements 42, which together form a projecting profile that is adapted to complement (e.g. in size and shape) the recess 28 formed at each side region 25 of the elongate elements 21 making up the first and second portions 31 , 32 of the mounting rail 20.
  • the projecting elements 42 at the lower region of the connecting bracket 40 are formed as opposite flange elements incorporating a right-angle or 90° step-shape, which extend across the plate-like body part 41 of the bracket 40.
  • this projecting profile is sized and shaped for receipt within the recess 28.
  • the two projecting elements 42 could be replaced by a single element or by multiple elements with no overall change in function.
  • the connecting elements further include two relatively short and straight flange elements 43 which project substantially perpendicularly from the plate-like body part 41 and extend across it parallel to one another.
  • a hole or aperture 44 is provided through the plate-like body part 41 approx.
  • the spacing 45 between the straight flange elements 43 is preferably sized to accommodate the upper and lower projections 26, 27 formed at the side regions 25 of the elongate elements 21 with relatively little "play" there-between.
  • the first portion 31 of each mounting rail 20 - i.e. the portion consisting of one or more elongate elements 21 forming a uniformly and coaxially extensive portion of the mounting rail 20 - is initially positioned extending across the tops of the beams B.
  • the various first portions 31 are arranged substantially parallel to one another and spaced apart at approximately regular intervals 1 1 across the tops of the beams B.
  • the flange-like footings 23 of the one or more elongate elements 21 making up each first portion 31 stand, and thereby support the mounting rail 20, upon the upper surface U of each of the beams B of the roof structure.
  • the first portion 31 of each mounting rail 20 is securely fixed to each of the beams B with angle brackets 12 in combination with hammer-head bolts 13 and screws 14.
  • the angle brackets 12 are fixed to the beams B using screws 14 and the first portion 31 of each mounting rail 20 is secured to the angle bracket 12 by a hammerhead bolt 13.
  • a head 15 of the bolt 13 is received in the recess 28 at the side region 25 of the elongate element 21 and a threaded end 16 of the bolt 13 is fastened to the bracket via a nut 17, which draws the head 15 to bear against the opposite flanges elements 29, 30 of the upper and lower projections 26, 27.
  • the first portion 31 of the mounting rail 20 is thereby securely held in position.
  • the second portion 32 is then connected to the first portion 31 via the connecting bracket 40.
  • the second portion 32 of the mounting rail 20 is arranged in alignment with and adjacent to the first portion 31 , but is displaced or offset below the first portion 31 such that there is an overlap in the longitudinal direction in the region 33. While allowing for this longitudinal overlap 33, the elongate element or section 21 which is to form the second portion 32 of the mounting rail 20 is selected or cut to have a length sufficient to abut a facing surface F of the beam B' at the periphery of the area for installing the solar panel array.
  • this beam B' still supports the edge region E of the original roof cladding C at the periphery of the area for the installation of the solar panel array.
  • the upper surface of this beam B' is not available for supporting the mounting rail 20 in the same way as with the first portion 31.
  • the second portion 32 of the mounting rail 20 is arranged to be aligned with, but to overlap longitudinally below the first portion 31 and such that an end 34 of the second portion 32 is positioned for abutment with the facing surface F of that beam B'. the first portion 31 and such that an end 34 of the second portion 32 is positioned for abutment with the facing surface F of that beam B'.
  • a connecting bracket 40 is provided preferably on both sides 25 of the second portion 32, by inserting the projecting profile formed by the projecting elements 42 of each bracket 40 into the corresponding recess or channel 28 at the respective side region 25 of the elongate element 21 forming the second portion 32.
  • the bracket 40 engages the second portion 32 with only a little "play" within the recess 28, although preferably such that the bracket 40 is readily slidable along the channel 28 by hand.
  • the plate-like body part 41 of the bracket 40 is adapted to extend between the respective side regions 25 of the first portion 31 and the second portion 32 of the mounting rail 20.
  • a head 15 of the bolt 13 is inserted into the recess or channel 28 of the first portion 31 and is slid there-along for registration with the hole or aperture 44 formed in the plate-like body part 41 of the bracket.
  • the bracket 40 is securely fastened to the first portion 31 via a nut 17 which is screwed onto the threaded end 16.
  • sheets of a cladding material 50 are then arranged over the mounting rails 20 to cover the area of the roof in which the original cladding C was removed. Because the cladding material 50 is only added to the mounting system 100 after the mounting rails 20 have already been secured to the roof structure, the cladding material does not inhibit the fixation of the mounting rails 20 to the roof structure. On the contrary, the operators are able to secure the mounting rails 20 to the beams B of the roof structure directly.
  • the first portion 31 of the mounting rail 20 may comprise a number of the individual elongate elements or sections 21 connected together so as to be coaxial with one another.
  • an insert connector designed to be snugly received within the central hollow channel 22 of the element 21 may be employed, with one half of the insert being received in one of the elements 21 and the other half being received in the other to ensure axial alignment.
  • the operators installing the solar panel array may optionally add an additional beam at an intermediate spacing between the main beams B of the roof structure.
  • a flexible sheet material 70 which is visible for example in Fig.

Abstract

The present invention provides a mounting system (100) for mounting one or more solar panels (S), comprising a mounting frame (10) having a plurality of elongate mounting members (20) adapted to be arranged and secured substantially parallel and laterally spaced apart from one another for supporting the one or more solar panels (S) thereon. Each of the mounting members (20) comprises an elongate first portion (31) having a first longitudinal axis (X31), and an elongate second portion (32) having a second longitudinal axis (X32). The mounting system (100) further comprises connection means (40) in the form of a bracket, which is adapted to connect the first portion (31) and the second portion (32) of a respective mounting member (20) such that the second longitudinal axis (X32) is displaced or offset relative to the first longitudinal axis (X31). The invention also provides a connecting bracket (40) for the mounting system (100), comprising a body part (41) adapted to extend between the first portion (31) and the second portion (32) of the mounting rail (20); and connecting elements (42-44) provided on the body part (41) for engagement with a side region (25) of the first portion (31) and/or a side region (25) of the second portion (32) of the mounting rail. The bracket (40) is adapted to interconnect the first portion (31) and the second portion (32) of the respective mounting rail (20) such that a longitudinal axis (X32) of the second portion (32) is displaced or offset relative to a longitudinal axis (X31) of the first portion (31).

Description

MOUNTING SYSTEM FOR SOLAR PANELS AND CONNECTING BRACKET FOR SAME
Technical Field
The present invention relates to a mounting system for mounting solar panels and to a connecting bracket for use in such a mounting system.
The mounting system of the invention and the associated connecting bracket are particularly suitable for use in mounting solar panels on a rooftop or similar structure, and it will be convenient to hereinafter describe the invention in this exemplary context. It should be appreciated, of course, that the mounting system of the invention is not limited to use on rooftops, but may also be employed where the solar panels are to be mounted on any of a variety of supporting frameworks.
Background of the Invention
As a result of the increasing trend towards adoption of renewable energy sources, the installation of solar panel arrays is gaining in popularity, not only for industrial and institutional applications, but also in the domestic and rural environments. Whether for the industrial, institutional, domestic or rural environment, the solar panels are often mounted on the rooftops of buildings - most typically in the area where the solar energy is required. Roof structures are particularly convenient for this purpose as they present a large surface area directed towards the sun and are often largely out of view from the normal visual perspective, thereby rendering the installations relatively unobtrusive.
When installing solar panel arrays on a rooftop, it is often desirable and necessary to remove a portion of the original roof cladding, such as tiles or sheet material, in the area of the roof at which the solar panels are to be arranged. This is often necessary to gain access to the structural framework of the roof, upon which the solar panel array is ultimately to be supported and secured. Removal of the original cladding material in this area also enables the solar panel array to be set into the roof, thereby giving the array a significantly lower profile and making it less conspicuous than if it were simply mounted on top of the original outer cladding of the roof.
The structural framework of a roof typically comprises an arrangement of beams and bearing members such as rafters, battens, purlins and/or stringers. These roof beams are typically timber elements, although other materials such as steel are also known. A mounting system for mounting the solar panels will typically include a mounting frame which is secure to and supported on the structural elements of the roof. The mounting frame typically includes a plurality of elongate mounting members which are arranged and secured substantially parallel and laterally spaced apart from one another for supporting the solar panels thereon, with the solar panels arranged extending between the individual mounting members. These elongate mounting members of the mounting frame are therefore typically positioned on and extend across the beams of the roof framework.
A problem confronted when arranging and securing the mounting frame on the roof beams is that, after the area of outer roof cladding has been removed for installation of the solar panel array, the remaining roof cladding at the periphery of the exposed area of the roof structure still needs to be supported on the beams of the roof framework. In other words, the beams of the roof structure at the periphery of the area for receiving the solar panel array are required to support the original roof cladding which has not been removed. This presents a problem with those beams receiving the elongate members of the mounting frame because those beams will be at least partially covered by the original roof cladding.
Another problem concerns the replacement of roof cladding in the area of the roof in which the solar panel array is to be installed. In the past, although it has been known to provide a replacement waterproof membrane under the solar panel units, this has not always led to a simple overall installation procedure. In particular, the design of previous arrangements has often impeded the reliable and secure attachment of the mounting frame to the roof structure.
The present invention is therefore directed to overcoming the above problems. In particular, the invention aims to provide a new and improved mounting system for mounting solar panels, with which a structure, such as a roof, may optimally support both a mounting frame for the solar panels as well as waterproof cladding material. In addition, the invention aims to provide a new mounting system for solar panels with which the procedure for installing the array is improved and/or simplified.
Summary of the Invention
According to one aspect, the present invention provides a mounting system for mounting one or more solar panels, the mounting system comprising a plurality of elongate mounting members adapted to be arranged and secured substantially parallel and laterally spaced apart from one another for supporting one or more solar panels thereon. In use, the solar panels are positioned to extend between adjacent mounting members. Each of the mounting members comprises an elongate first portion having a first longitudinal axis, and an elongate second portion having a second longitudinal axis. The mounting system further comprises connection means for connecting the first portion and the second portion of a respective mounting member such that the second longitudinal axis is displaced or offset relative to the first longitudinal axis. In this regard, the second longitudinal axis is typically displaced or offset in a direction perpendicular to the first longitudinal axis.
In a preferred form of the invention, the connection means is adapted to connect the first portion and the second portion of the respective mounting member such that the second portion partially overlaps with the first portion in a longitudinal direction. The first portion and the second portion are typically adjacent to and substantially parallel to one another and/or generally aligned with one another. Preferably, the connection means is adapted to connect the first portion and the second portion of the respective mounting member such that the second longitudinal axis is displaced - A -
or offset relative to the first longitudinal axis by a distance approximately corresponding to a cross-sectional dimension of the first portion. In this respect, the first portion and the second portion of the respective mounting member may have substantially the same configuration in cross-section, i.e. the same configuration perpendicular to their respective longitudinal axes. Preferably, also, the second portion forms an end portion of the respective mounting member. The second portion may, for example, be arranged below the first portion in the respective mounting member.
By developing a mounting system in which an elongate mounting member has one portion that extends offset or displaced from another portion thereof, the inventors have conceived a system with which the problem of the beams of the roof structure supporting both the original roof cladding as well as the mounting members of the solar panel array can be solved. In particular, by virtue of the lateral displacement or offset of the second portion of the mounting member relative to the first portion, i.e. such that it is longitudinally non-coaxial, the present invention enables the elongate mounting member to extend at an altered elevation at this second portion - typically an end portion of the mounting member. As such, the end portion of the mounting member can then be connected to a side face of a roof beam at the periphery of the area for receiving the solar panel array, while an upper surface of that same roof beam is still able to support the original roof cladding material, which has not been removed.
In a preferred form of the invention, the connection means comprises a bracket member adapted to engage with a side region of the first portion and/or a side region of the second portion of the respective mounting member. The bracket member may comprise one or more connecting elements for engagement with the side regions of the first portion and the second portion of the respective mounting member. Further, the connection means may additionally include an engagement structure formed in the side region(s) of the first portion and/or the second portion of the respective mounting member, with the engagement structure preferably including one or more recess for receiving and engaging the one or more connecting elements of the bracket member. The one or more connecting elements of the bracket member may, for example, comprise a projecting profile adapted to complement the recess formed in the side region(s) of the first portion and/or the second portion of the respective mounting member.
In a preferred form of the invention, the mounting system further comprises a roof cladding material adapted to be attached to and supported by the elongate mounting members. The cladding material is adapted to be arranged between the mounting members and the one or more solar panels. An upper surface of the elongate mounting members thus preferably bears against an underside of the roof cladding material. The roof cladding material may, for example, comprise a sheet material having one or more corrugations or channels formed therein. In that case, the sheet material is preferably designed to be supported such that the mounting members are arranged to extend within the corrugations or channels formed in the sheet material. The sheet material is desirably formed from a polymer plastics material and is both impervious to water and weather resistant. The sheet material may optionally comprise a plurality of individual panels adapted to be arranged overlapping one another, the panels typically being of a rigid or semi-rigid construction.
In a preferred form of the invention, the mounting system further comprises at least one fastening arrangement associated with each of the elongate mounting members, wherein each fastening arrangement is adapted to fasten or secure both the roof cladding material and one or more solar panels to the respective mounting member.
In a preferred form of the invention, each fastening arrangement comprises a clamping member for securely attaching the roof cladding material to the respective mounting member. Furthermore, the fastening arrangement preferably comprises a clip device for securely attaching the one or more solar panels to the mounting member, with the clip device being designed to be provided on or carried by the clamping member. In this regard, the clamping member may be elongate, preferably formed as a rail element, and is preferably designed to extend longitudinally of the mounting member. As such, the position of the clip device may be adjustable along the length of the elongate, rail-like clamping member. The clamping member may also present a seating surface on an upper side thereof for receiving and supporting a solar panel.
According to another aspect, the present invention provides a bracket member for interconnecting an elongate first portion and an elongate second portion of a mounting member in a mounting system for mounting one or more solar panels. The bracket member is adapted to interconnect the first portion and the second portion of the respective mounting member such that a longitudinal axis of the second portion is displaced or offset relative to (i.e. not coaxial with) a longitudinal axis of the first portion.
In a preferred form of the invention, the bracket member comprises one or more connecting elements for engagement with the first portion and the second portion of the mounting member when the first portion and the second portion are positioned in alignment with one another. In particular, the connecting elements of the bracket member are adapted for engagement with the first portion and/or the second portion of the mounting member such that the second portion is arranged to partially overlap with the first portion in a longitudinal direction. That is, the first portion and the second portion are preferably connected such that they extending next to, and in parallel with, one another.
In a particularly preferred form, the one or more connecting elements of the bracket member are adapted for engagement with a side region of the first portion and/or a side region of the second portion of the mounting member. In this regard, the one or more connecting elements of the bracket member preferably comprise a projecting profile adapted to complement one or more recess formed in the side region of the first portion and/or the second portion, whereby the projecting profile is adapted to be received in and to engage with the respective complementary recess in the side region of the first and/or second portions. In a preferred form of the invention, the bracket member comprises a body part upon which the one or more connecting elements are provided. The body part is adapted to extend between the first portion and the second portion of the mounting member and is preferably formed from plate material. As such, the body part may comprise a plate-like element.
In a preferred form of the invention, the bracket member may comprise an aperture which accommodates a connecting element, such as a bolt, adapted to be received in and to engage with a respective complementary recess in a side region of the first or second portion of the mounting member. The connecting element, e.g. bolt, may in this case be detachable from the bracket member.
According to a further broad aspect, the present invention provides a mounting system for mounting one or more solar panels, the mounting system comprising: a plurality of elongate mounting members adapted to be arranged and secured laterally spaced apart and substantially parallel to one another for supporting one or more solar panels thereon, and roof cladding material adapted to be attached to and supported by the elongate mounting members, wherein the roof cladding material is arranged between the mounting members and the one or more solar panels.
In a preferred form of the invention, each of the mounting members comprises an elongate first portion with a first longitudinal axis, and an elongate second portion with a second longitudinal axis. The mounting system further comprises connection means adapted to connect the first portion and the second portion of a respective mounting member such that the second longitudinal axis is displaced or offset relative to the first longitudinal axis.
In a preferred form of the invention, the mounting system further comprises at least one fastening arrangement associated with each of the elongate mounting members, wherein each fastening arrangement is adapted to fasten or secure both the roof cladding material and one or more solar panels to the respective mounting member. In a preferred form of the invention, an upper surface of the elongate mounting members bears against an underside of the roof cladding material. The roof cladding material may comprise sheet material having one or more corrugations or channels formed therein, the sheet material optionally comprising a plurality of individual panels. The sheet material is preferably adapted to be supported such that each of the elongate mounting members is arranged to extend along a respective corrugation or channel formed in the sheet material.
In a preferred form of the invention, the mounting system includes at least one and preferably a plurality of solar panels for assembly with the mounting members in a solar panel array.
According to a further aspect, the invention also provides a method of mounting one or more solar panels, comprising the steps of: arranging an elongate first portion of an elongate mounting member for supporting one or more solar panels thereon on or across beams of a supporting structure, such as a roof framework; arranging an elongate second portion of the elongate mounting member adjacent to and in general alignment with, but axially offset from, the first portion; and securely interconnecting the first portion and the second portion of the mounting member - i.e. such that a longitudinal axis of the second portion is displaced or offset relative to a longitudinal axis of the first portion. Preferably, the elongate first portion of the mounting member is fixed or secured to the supporting structure before the second portion of that mounting member is interconnected with the first portion.
In a preferred form of the method of the invention, a plurality of elongate mounting members, each of which has an elongate first portion and an elongate second portion, are fixed or secured on the supporting structure such that a longitudinal axis of each second portion is displaced or offset relative to a longitudinal axis of each respective first portion. Furthermore, the mounting members are arranged and secured substantially parallel and laterally spaced apart from one another for supporting one or more solar panels thereon. According to yet another aspect, the invention provides a method of mounting one or more solar panels, comprising the steps of: arranging and securing a plurality of elongate mounting members laterally spaced apart and substantially parallel to one another on a structure, such as a roof framework, for supporting one or more solar panels thereon, and arranging roof cladding material to be supported by the elongate mounting members, wherein the roof cladding material is arranged between the mounting members and the one or more solar panels to be supported thereon. The cladding material is preferably directly attached to the mounting members.
The terms "upper", "lower", "above", "below", "topside", "underside", "lateral", "laterally" and other similar terms used herein in respect of various parts of the mounting system of the invention are intended to be given their ordinary meaning in view of the normal or in-use orientation of the mounting system described herein. It will be appreciated, however, that other interpretations of these terms may be appropriate depending on the particular orientation of the system and/or its respective parts at the time.
Brief Description of the Drawings
The above and further features and advantages of the invention will become more readily apparent from the following detailed description of preferred embodiments of the invention with reference to the accompanying drawings, in which like reference characters identify like features, and in which:
Fig. 1 is a perspective view of a mounting system for solar panels according to a preferred embodiment of the invention shown assembled with the solar panels on part of a rooftop;
Fig. 2 is a cross-sectional view of the mounting system and rooftop shown in Fig. 1 taken in the direction of the arrows H-Il; Fig. 3 is a detailed side view of an end portion of a mounting member in the region marked "Z" of the mounting system shown in Fig. 2;
Fig. 4 is a perspective view in the direction marked "View A" in Fig. 3 of the end portion of the mounting member and its attachment to a side face of a beam of the roof structure;
Fig. 5 is a cross-sectional view of the mounting system and rooftop shown in Fig. 1 taken in the direction of the arrows V-V;
Fig. 6 is a detailed view of the end portion of the mounting member in the region marked "Z" of the mounting system shown in Fig. 5;
Fig. 7 is a detailed perspective view of the end portion of the mounting member in the region of the mounting system shown in Fig. 3;
Fig. 8 is an end view of a mounting member of the mounting system according to the preferred embodiment of the invention shown in Fig. 1 ;
Fig. 9 is a perspective view of the mounting member shown in Fig. 8;
Fig. 10 is a perspective view of a bracket member for use in the mounting system of the present invention;
Fig. 1 1 is a side view of the bracket member shown in Fig. 10;
Fig. 12 is a cross-sectional view of the mounting system and rooftop shown in Fig. 1 taken in the direction of the arrows XIl-XII;
Fig. 13 is a detailed view of the end portion of the mounting member in the region marked "Z" of the mounting system shown in Fig. 12; and Fig. 14 is a detailed perspective view of a fastening arrangement in the mounting system of the invention shown in Fig. 13.
Detailed Description of the Preferred Embodiments
With reference to Fig. 1 of the drawings, a mounting system 100 according to a preferred embodiment of the invention is illustrated in an assembled state installed on a rooftop R. The mounting system 100 shown in Fig. 1 has been designed to carry ten rectangular solar panels S securely fixed to a mounting frame 10 of the mounting system in a rectangular array. Seven of the solar panels S are shown mounted on the mounting frame 10 and three are absent to reveal parts of the underlying mounting system 100, which will be described in more detail with reference to the following drawings. The solar panels S in this embodiment comprise glass photovoltaic panels or modules and typically have a metal frame or rim (e.g. of aluminium) extending around their outer periphery, which facilitates the fastening of the solar panels S to the mounting frame 10. The solar panels S are usually rectangular and typically present a collecting surface with an area in the range of about 0.5 m2 to about 4 m2, though the area and the dimensions of the panels are not critical to the present invention.
The rooftop R shown in Fig. 1 of the drawings, upon which the mounting system 100 of the present invention is installed, includes a conventional roof cladding C in the form of corrugated sheet material, the corrugations having a generally trapezoidal shape. This roof cladding C may, for example, comprise galvanized or coated steel sheeting, as is known in the art, or alternatively synthetic (e.g. polymer plastic) sheeting. The roof cladding C is supported on and securely affixed to a series of roof beams B, the beams forming a framework of the roof structure for the building. These roof beams B may be rafters, battens, purlins or stringers, as are typical in a roof structure, and in this example they are timber elements, although steel roof beams are also known. The mounting frame 10 of the mounting system 100 comprises a plurality of elongate mounting members 20, which in this particular embodiment are made up of individual straight elements having a substantially uniform or constant cross- section, and which are formed, for example, as extruded aluminium sections. Thus, the mounting members 20 are elongate structural elements 21 upon which the solar panels are mounted and supported within the frame 10 of the mounting system 100. In the present embodiment the mounting members 20 will hereafter also be referred to as mounting "rails", as they are often known in the art.
When installing the solar panel mounting system 100 of this particular embodiment of the invention, an area of the original roof cladding C is removed - for example, by cutting through the corrugated sheeting of that roof cladding C - to expose the beams B of the roof structure for installation of the mounting system 100 thereon. The edge region E of the original roof cladding C at the periphery of the area where that cladding material has been removed can be seen in Fig. 1 , but is more clear from Fig. 2 and Fig. 3 of the drawings.
Fig. 2 of the drawings illustrates a longitudinal cross-section of the mounting system 100 shown in Fig. 1 taken along the lines H-Il. Thus, in Fig. 2, the beams B of the roof structure are shown in cross-section and a single elongate mounting member or mounting rail 20 of the mounting frame 10 can be seen in side-view extending across an upper surface of the beams B in a direction generally transverse or perpendicular to the longitudinal extent of the beams B. The rooftop R having the corrugated cladding C will usually be at least slightly angled or pitched in the direction the corrugations extend so that the corrugations operate as channels for carrying or directing rainwater there-along into a drain or gutter and off the roof. An angled or pitched roof is not essential for the mounting system 100 of the invention, but is often encountered in practice. For simplicity, the cross-section of Fig. 2 is shown in a horizontal orientation (i.e. without the roof pitch) but, in practice, the rooftop R is angled to slope downwardly from right to left in this case. The horizontal representation of Fig. 2 is useful because it helps illustrate that the upper surfaces of the roof beams B together form seating surfaces which generally lie within a common plane, and these surfaces ordinarily support the sheet material of roof cladding C. As this cladding C has been partially removed for the installation of the solar panel array, however, a large section of these beam surfaces are now free for the support and attachment of the mounting rails 20 in the mounting system 100.
At opposite ends of the mounting rail 20 shown in Fig. 2 of the drawings, a kind of discontinuity or change in the longitudinal elevation of the mounting rail 20 can be seen. This is illustrated more clearly in Fig. 3. This configuration of the elongate mounting rails 20 forms an aspect of the mounting system 100 of the invention and will be described in more detail with reference to Figs. 2 to 7 of the drawings. Firstly, however, it will be noted that each of the mounting rails 20 in this embodiment includes a plurality of elongate elements or sections 21 which are interconnected with one another. Further, each of these elements or sections 21 which are combined to form the mounting rail 20 has the same cross-sectional configuration. An individual one of these elements or sections 21 is illustrated in Fig. 8 and Fig. 9 of the drawings.
With reference briefly to Fig. 8 and Fig. 9, the element or section 21 has a generally rectangular cross-section and includes a central cavity 22 which extends along the length of thereof. On an underside of the element 21 , two flange-like footings 23 are provided which also extend along the length of the element and present planar surfaces upon which the element 21 may be stably supported. At the upper side of the elongate element 21 , a plain surface 24 is provided which, as will be seen later, may form a bearing surface for supporting roof cladding material. Lateral side regions 25 of the elongate element 21 include upper and lower projections 26, 27, which together partially encompass a recess 28 formed in each side region 25. Each recess 28 extends along the respective side region 25 in the form of a channel. The upper and lower projections 26, 27 are shaped as right-angled sections and include oppositely extending upper and lower flange elements 29, 30 which define a gap there-between opening into the recess or channel 28 at the sides 25 of the elongated element 21. With reference again now to Fig. 3, the region denoted "Z" in Fig. 2 of the drawings is shown in detail. The mounting rail 20 can be seen to comprise an elongate first portion 31 and an elongate second portion 32, and each of these first and second portions 31 , 32 comprises at least one elongate element 21 as shown in Fig. 8 and Fig. 9. As is clearly apparent, the elongate second portion 32 is offset or displaced with respect to the first portion 31 so that it is not coaxial with the first portion 21. In particular, the second portion 32 forms an end portion of the mounting rail 20 and, although it partially overlaps with the first portion 31 in a region 33, it extends below the first portion 31. Thus, a central longitudinal axis X32 of the second portion 32 is displaced or offset a distance d in a downward direction from a central longitudinal axis X31 of the first portion 31. This offset or displaced configuration at the end portion of the mounting rail 20 in the region denoted "Z" in Fig. 2 is the same at the opposite end portion of the mounting rail 20, as can be seen.
The axially offset or displaced configuration of the mounting rail 20 is effected via a connector means in the form of a bracket member 40. That is, the connector means or bracket member 40 is adapted for interconnecting the elongate first and second portions 31 , 32 of the mounting rail 20, such that the first portion 31 and the second portion 32 extend in the offset or displaced configuration shown in Fig. 3. For this reason, the bracket member 40 is also referred to herein as a connecting bracket. The specific configuration of the connecting bracket 40 in this embodiment of the invention is shown in detail in Figs. 10 and 11 of the drawings.
With reference now to Figs. 10 and 11 , the bracket 40 is typically fabricated as an integral component from a rigid and robust material, such as aluminium or steel or another metal. The bracket 40 comprises a body part 41 formed from plate material and is substantially flat and rectangular. In addition, the bracket 40 comprises connecting elements provided on the body part 41 for engagement with both the first and second portions 31 , 32 of the mounting rail 20 when these are brought into position adjacent one another. In this regard, the connecting elements at a lower region of the bracket 40 comprise a pair of projecting elements 42, which together form a projecting profile that is adapted to complement (e.g. in size and shape) the recess 28 formed at each side region 25 of the elongate elements 21 making up the first and second portions 31 , 32 of the mounting rail 20. In this example, therefore, the projecting elements 42 at the lower region of the connecting bracket 40 are formed as opposite flange elements incorporating a right-angle or 90° step-shape, which extend across the plate-like body part 41 of the bracket 40. In this way, this projecting profile is sized and shaped for receipt within the recess 28. It will be appreciated, of course, that the two projecting elements 42 could be replaced by a single element or by multiple elements with no overall change in function. At an upper region of the connecting bracket 40, the connecting elements further include two relatively short and straight flange elements 43 which project substantially perpendicularly from the plate-like body part 41 and extend across it parallel to one another. In addition, a hole or aperture 44 is provided through the plate-like body part 41 approx. centrally between the straight flange elements 43 for receiving a bolt, such as a hammer-head bolt. The spacing 45 between the straight flange elements 43 is preferably sized to accommodate the upper and lower projections 26, 27 formed at the side regions 25 of the elongate elements 21 with relatively little "play" there-between.
The manner in which the bracket 40 operates to interconnect the first and second portions 31 , 32 of the mounting rail 20 in the mounting system 100 of the present invention is clearly illustrated in Figs. 5 to 7 of the drawings, particularly when the shape of the individual elongate elements 21 (shown in Figs. 8 and 9) making up the mounting rail 20 is kept in mind. With reference firstly to Figs. 2 and 7 as well as to
Figs. 12 and 13, however, when assembling the mounting frame 10 of the mounting system 100, the first portion 31 of each mounting rail 20 - i.e. the portion consisting of one or more elongate elements 21 forming a uniformly and coaxially extensive portion of the mounting rail 20 - is initially positioned extending across the tops of the beams B. As there are a number of mounting rails 20, the various first portions 31 are arranged substantially parallel to one another and spaced apart at approximately regular intervals 1 1 across the tops of the beams B. In this regard, the flange-like footings 23 of the one or more elongate elements 21 making up each first portion 31 stand, and thereby support the mounting rail 20, upon the upper surface U of each of the beams B of the roof structure.
Furthermore, as can be clearly seen in Figs. 7 and 13 of the drawings, the first portion 31 of each mounting rail 20 is securely fixed to each of the beams B with angle brackets 12 in combination with hammer-head bolts 13 and screws 14. For example, the angle brackets 12 are fixed to the beams B using screws 14 and the first portion 31 of each mounting rail 20 is secured to the angle bracket 12 by a hammerhead bolt 13. In this regard, a head 15 of the bolt 13 is received in the recess 28 at the side region 25 of the elongate element 21 and a threaded end 16 of the bolt 13 is fastened to the bracket via a nut 17, which draws the head 15 to bear against the opposite flanges elements 29, 30 of the upper and lower projections 26, 27. The first portion 31 of the mounting rail 20 is thereby securely held in position.
After the first portion 31 of each mounting rail 20 is fixed in position on the roof structure, the second portion 32 is then connected to the first portion 31 via the connecting bracket 40. As is particularly clear from Figs. 5 to 7 of the drawings, the second portion 32 of the mounting rail 20 is arranged in alignment with and adjacent to the first portion 31 , but is displaced or offset below the first portion 31 such that there is an overlap in the longitudinal direction in the region 33. While allowing for this longitudinal overlap 33, the elongate element or section 21 which is to form the second portion 32 of the mounting rail 20 is selected or cut to have a length sufficient to abut a facing surface F of the beam B' at the periphery of the area for installing the solar panel array. In this respect, it will be noted that the upper surface of this beam B' still supports the edge region E of the original roof cladding C at the periphery of the area for the installation of the solar panel array. Thus, the upper surface of this beam B' is not available for supporting the mounting rail 20 in the same way as with the first portion 31. Accordingly, the second portion 32 of the mounting rail 20 is arranged to be aligned with, but to overlap longitudinally below the first portion 31 and such that an end 34 of the second portion 32 is positioned for abutment with the facing surface F of that beam B'. the first portion 31 and such that an end 34 of the second portion 32 is positioned for abutment with the facing surface F of that beam B'.
At the same time, a connecting bracket 40 is provided preferably on both sides 25 of the second portion 32, by inserting the projecting profile formed by the projecting elements 42 of each bracket 40 into the corresponding recess or channel 28 at the respective side region 25 of the elongate element 21 forming the second portion 32. As the projecting profile of the elements 42 generally complements the recess or channel 28 in size and shape, the bracket 40 engages the second portion 32 with only a little "play" within the recess 28, although preferably such that the bracket 40 is readily slidable along the channel 28 by hand. When the second portion 32 of the mounting rail 20 is in alignment with the first portion 31 as shown in Figs. 6 and 7 of the drawings, and the projecting elements 42 of each bracket 40 are received within the recess or channel 28 of the second portion 32, then the hole or aperture 44 in the upper region of the bracket 40 will be aligned with the corresponding recess or channel 28 at the side region 25 of the elongate element 21 of the first portion 31 above. Furthermore, the upper and lower projections 26, 27 at the side regions 25 of the first portion 31 are received within the space 45 between the flange elements 43 of the bracket 40. In this regard, the plate-like body part 41 of the bracket 40 is adapted to extend between the respective side regions 25 of the first portion 31 and the second portion 32 of the mounting rail 20.
A hammer-head bolt 13, like that described above with reference to Fig. 13, is employed to secure the bracket 40 to the first portion 31 of the mounting rail 20. In particular, a head 15 of the bolt 13 is inserted into the recess or channel 28 of the first portion 31 and is slid there-along for registration with the hole or aperture 44 formed in the plate-like body part 41 of the bracket. When the threaded end 16 of the bolt 13 is inserted through the hole 44 in the bracket plate 41 , the bracket 40 is securely fastened to the first portion 31 via a nut 17 which is screwed onto the threaded end 16. By repeating this procedure on both sides of the mounting rail 20, both of the opposite side regions 25 of each of the first and second portions 31 , 32 of the mounting rail 20 are securely connected with one another as shown in Fig. 6. The end 34 of the second portion 32 is supported on and is rigidly secured to the beam B' at the periphery of the solar panel array by an angle bracket 12 like that described above with reference to Fig. 13. In particular, as clearly shown in Fig. 3 and Fig. 4 of the drawings, a further hammer-head bolt 13 may be inserted within a channel formed between the flange-like footings 23 of the elongate element 21 of the second portion 32 and secured to the angle bracket 12 in a similar fashion as the hammer-head bolt is secured to the bracket member 40. In this way, the end portion of the mounting rail 20 formed by the second portion 32 is also stably and securely fixed to the roof structure. This process of securing the second portion 32 of the mounting rail 20 is then repeated at the opposite end portion of the mounting rail 20 in Fig. 2 (i.e. opposite the end denoted by "Z").
After the mounting rails 20 of the solar panel mounting system 100 of the present invention have been secured in position on the roof structure, sheets of a cladding material 50 are then arranged over the mounting rails 20 to cover the area of the roof in which the original cladding C was removed. Because the cladding material 50 is only added to the mounting system 100 after the mounting rails 20 have already been secured to the roof structure, the cladding material does not inhibit the fixation of the mounting rails 20 to the roof structure. On the contrary, the operators are able to secure the mounting rails 20 to the beams B of the roof structure directly.
With reference to Fig 5 and Figs. 12 to 14 of the drawings, the cladding material 50 in this particular embodiment comprises one or more panels of relatively rigid corrugated sheet material. The corrugated sheet material may, for example, comprise polymer plastic sheet material or metal sheet material, but is in any case waterproof, robust and durable, and, of course, weather resistant. For example, multiple panels of the cladding material 50 may be arranged to extend in partial overlap with one another across the entire area of the roof surface exposed by removal of the original roof cladding C. At the laterally opposite side regions, an end section or end panel 51 is provided having an up-turned edge region 52 to overlap below the original roof cladding C, as shown in Fig. 5 and Fig. 12. In this particular example, the corrugations of the cladding material 50 are trapezoidal in shape, which has the advantage that they provide substantially planar or flat upper and lower seating or bearing surfaces. In this way, flat bases 53 of the troughs of the corrugations may seat or rest upon the upper surfaces U of the beams B, while the cavities 54 formed by the troughs may channel rainwater from the roof. Similarly, flat peaks 55 of the corrugations form a seating or bearing surface for attachment of solar panels S, as will be described further below, and cavities 56 formed by the peaks are preferably sized to encompass or accommodate the first portion 31 of the mounting rails 20 and the angle brackets 12 which rigidly attach the first portion 21 to the roof beams, as shown in Fig. 13. Furthermore, the height h of the corrugations is preferably such that the plain upper surface 24 of the mounting rail 20 is in very close proximity to, and/or bears against, an inner surface of that cladding material 50 in the region of the peak 55, as shown in Fig. 13.
After positioning the sheet cladding material 50 over the mounting frame 10 of the mounting system 100, the cladding material 50 is firstly to be securely attached to the mounting rails 20. The solar panels S are then placed upon the mounting rails 20 above the cladding material 50 and are also securely attached thereto. According to the present invention, both of these attachment procedures may be performed by means of a common fastening arrangement 60. That is, the fastening arrangement 60 is designed to secure the cladding material 50 to the mounting frame 10 of the mounting system 100 and also to secure the solar panels S to the mounting frame 10.
With reference to Figs. 6 and 7 and Figs. 12 to 13 of the drawings, the fastening arrangement 60 comprises a clamping element 61 which is designed to be fastened with self-tapping screws 62 through the cladding material 50 into the central cavity 22 of the first portion 31 of the mounting rail 20. The clamping element 61 is formed like an elongate rail-element and is designed to carry clip device 63 thereon, the position of the clip device being adjustable along the length of the clamping element 61. As can be seen in Fig. 12, when a solar panel S is positioned on the mounting system 100, the metal rim or frame which extends around the periphery of the solar panel S seats or rests upon the rail-like clamping element 61. The elongate nature of the clamping element 61 provides a degree of flexibility in the final positioning of the clip device 63 and the panel S on the mounting rails 20. The clip device 63 is provided with a threaded fastener 64, e.g. a screw, and a head 65, which by turning the screw 64 can be tightened against the metal rim or the solar panel S (e.g. using a screw-driver) to fasten the solar panel to the respective mounting rail 20.
It will be appreciated that the above description of the preferred embodiments of the invention with reference to the drawings has been made by way of example only. Accordingly, a person skilled in the art will appreciate that various changes, modifications and/or additions may be made to the parts particularly described and illustrated without departing from the scope of the invention as defined in the appended claims.
For example, an ordinary practitioner will appreciate that the first portion 31 of the mounting rail 20 may comprise a number of the individual elongate elements or sections 21 connected together so as to be coaxial with one another. In this regard, an insert connector designed to be snugly received within the central hollow channel 22 of the element 21 may be employed, with one half of the insert being received in one of the elements 21 and the other half being received in the other to ensure axial alignment. Furthermore, it will be appreciated that, if the beams B of the roof structure are relatively widely spaced, the operators installing the solar panel array may optionally add an additional beam at an intermediate spacing between the main beams B of the roof structure. In addition, it will be noted that a flexible sheet material 70, which is visible for example in Fig. 3, is typically employed to provide a transition from the panels of the cladding material 50 to the original roof cladding C. This flexible sheet material 70 will typically be formed of a polymer plastic material, as is known in the art, and facilitates water run-off from the cladding material 50 to the original roof cladding C.

Claims

Claims:
1. Mounting system (100) for mounting one or more solar panels (S), comprising: a plurality of elongate mounting members (20) adapted to be arranged and secured substantially parallel and laterally spaced apart from one another for supporting one or more solar panels (S) thereon, each of the mounting members (20) comprising an elongate first portion (31) having a first longitudinal axis (X31), and an elongate second portion (32) having a second longitudinal axis (X32); and connection means (40) adapted to connect the first portion (31 ) and the second portion (32) of a respective mounting member (20) such that the second longitudinal axis (X32) is displaced or offset relative to the first longitudinal axis (X31).
2. Mounting system (100) according to claim 1 , wherein the connection means (40) is adapted to connect the first portion (31) and the second portion (32) of the respective mounting member (20) such that the first portion (31 ) and the second portion (32) extend in alignment with one another, and such that the second longitudinal axis (X32) is displaced or offset in a direction substantially perpendicular to the first longitudinal axis (X31).
3. Mounting system (100) according to claim 1 or claim 2, wherein the connection means (40) is adapted to connect the first portion (31 ) and the second portion (32) of the respective mounting member (20) such that the second portion (32) partially overlaps with the first portion (31 ) in a longitudinal direction.
4. Mounting system (100) according to any one of the preceding claims, wherein the second portion (32) forms an end portion of the respective mounting member (20).
5. Mounting system (100) according to any one of the preceding claims, wherein the second portion (32) is arranged below the first portion (31 ) in the respective mounting member (20).
6. Mounting system (100) to according to any one of the preceding claims, wherein the second longitudinal axis (X32) is displaced or offset relative to the first longitudinal axis (X31) by a distance approximately corresponding to a cross-sectional dimension of the first portion (31 ); and/or wherein the first portion (31 ) and the second portion (32) of the respective mounting member (20) have substantially the same configuration in cross-section, i.e. the same configuration perpendicular to their respective longitudinal axes (X31, X32).
7. Mounting system (100) according to any one of the preceding claims, wherein the connection means (40) comprises a bracket member adapted to engage with a side region (25) of the first portion (31 ) and a side region (25) of the second portion (32) of the respective mounting member (20).
8. Mounting system (100) according to claim 7, wherein the bracket member (40) comprises one or more connecting elements (42-44; 13) for engagement with the side regions (25) of the first portion (31 ) and the second portion (32) of the respective mounting member (20).
9. Mounting system (100) according to claim 8, wherein the connection means includes an engagement structure (26-30) formed in the side regions (25) of each of the first portion (31 ) and the second portion (32) of the respective mounting member (20), wherein the engagement structure (26-30) preferably includes one or more recess (28) for receiving and engaging the one or more connecting elements (42-44; 13) of the bracket member (40).
10. Mounting system (100) according to claim 9, wherein the one or more connecting elements (42-44; 13) of the bracket member (40) comprise a projecting profile adapted to complement the recess (28) formed in the side regions (25) of the first portion (31 ) and/or the second portion (32) of the respective mounting member (20).
1 1. Mounting system (100) according to any one of the preceding claims, further comprising a roof cladding material (50) adapted to be attached to and supported by the elongate mounting members (20), wherein the roof cladding material (50) is arranged between the mounting members (20) and the one or more solar panels (S), and wherein an upper surface (24) of the elongate mounting members (20) preferably bears against an underside of the roof cladding material (50).
12. Mounting system (100) according to claim 1 1 , wherein the roof cladding material (50) comprises a sheet material, preferably having one or more corrugations or channels formed therein, with the sheet material optionally comprising a plurality of individual panels.
13. Mounting system (100) according to claim 12, wherein the sheet material is adapted to be supported such that the elongate mounting members (20) are arranged within and extend along the corrugations or channels formed in the sheet material.
14. Mounting system (100) according to any one of claims 11 to 13, further comprising one or more fastening arrangement (60) associated with each of the elongate mounting members (20), wherein each fastening arrangement (60) is adapted to fasten or secure both the roof cladding material (50) and one or more solar panels (S) to the mounting member (20).
15. Mounting system (100) according to claim 14, wherein each fastening arrangement (60) comprises a clamping member (61 , 62)) for securely attaching the roof cladding material (50) to the respective mounting member, and wherein a clip device (63) is provided on the clamping member (61 ) for securely attaching the one or more solar panels (S) to the mounting member.
16. Mounting system (100) according to claim 15, wherein the clamping member (61 ) is elongate, preferably formed as a rail element, and extends longitudinally of the mounting member (20), and wherein the clip device (63) is adjustably movable along the length of the clamping member (61 ).
17. Mounting system (100) for mounting one or more solar panels (S), comprising: a plurality of elongate mounting members (20) adapted to be arranged and secured laterally spaced apart and substantially parallel to one another for supporting one or more solar panels (S) thereon, and roof cladding material (50) which is attached to and supported by the elongate mounting members (20), wherein the roof cladding material (50) is arranged between the mounting members (20) and the one or more solar panels (S) to be supported thereon.
18. Mounting system (100) according to claim 17, wherein each of the mounting members (20) comprises an elongate first portion (31 ) with a first longitudinal axis (X31), and an elongate second portion (32) with a second longitudinal axis
(X32); the mounting system (100) further comprising connection means (40) adapted to connect the first portion (31 ) and the second portion (32) of a respective mounting member (20) such that the second longitudinal axis (X32) is displaced or offset relative to the first longitudinal axis (X31).
19. Mounting system (100) according to claim 17 or claim 18, wherein an upper surface (24) of the elongate mounting members bears against an underside of the roof cladding material (50); and/or wherein the roof cladding material (50) comprises sheet material having one or more corrugations or channels formed therein, the sheet material optionally comprising a plurality of individual panels; and/or wherein the sheet material is adapted to be supported such that each of the elongate mounting members is arranged within and extends along a respective corrugation or channel formed in the sheet material.
20. Mounting system (100) according to any one of claims 17 to 19, further comprising at least one fastening arrangement (60) associated with each of the elongate mounting members, wherein each fastening arrangement is adapted to fasten or secure both the roof cladding material (50) and one or more solar panels (S) to the mounting member (20).
21. Mounting system (100) according to claim 20, wherein the fastening arrangement (60) comprises a clamping element (61 ) for securely attaching the cladding material (50) to the respective mounting member (20), and wherein a clip device (63) is provided on the clamping element for securely attaching the one or more solar panels (S) to the mounting member (20).
22. Mounting system (100) according to claim 21 , wherein the clamping element (61 , 62) is elongate, preferably formed as a rail element, and extends longitudinally of the mounting member (20), and wherein a position of the clip device (63) is adjustable along the length of the clamping element.
23. Mounting system (100) according to any one of the preceding claims, further comprising at least one and preferably a plurality of solar panels for assembly with the mounting members in a solar panel array.
24. Bracket member (40) for interconnecting an elongate first portion (31 ) and an elongate second portion (32) of a mounting rail (20) in a mounting system (100) for mounting one or more solar panels (S), the bracket member (40) comprising: a body part (41 ) adapted to extend between the first portion (31 ) and the second portion (32) of the mounting rail (20); and connecting elements (42-44) provided on the body part (41 ) for engagement with a side region (25) of the first portion (31 ) and/or a side region (25) of the second portion (32) of the mounting rail; wherein the bracket member is adapted to interconnect the first portion (31 ) and the second portion (32) of the respective mounting rail (20) such that a longitudinal axis (X32) of the second portion (32) is displaced or offset relative to a longitudinal axis (X31) of the first portion (31 ).
25. Bracket member (40) according to claim 24, wherein the connecting elements (42-44) engage with the side region (25) of the first portion (31 ) and/or the side region (25) of the second portion (32) of the mounting rail (20) when the second portion (32) is arranged to partially overlap with the first portion (31 ) in a longitudinal direction.
26. Bracket member (40) to according to claim 24 or claim 25, wherein the one or more connecting elements (42-44) of the bracket member (40) comprise a projecting profile adapted to complement one or more recess (28) formed in the side region(s) (25) of the first portion and/or the second portion, whereby the projecting profile is adapted to be received in and to engage with the respective recess (28) in the side region(s) (25) of the first portion and/or the second portion.
27. Bracket member (40) to according to any one of claims 24 to 26, wherein the body part (41 ) comprises a plate-like element.
28. Method of mounting one or more solar panels, comprising the steps of: arranging an elongate first portion of an elongate mounting member for supporting one or more solar panels thereon on and/or across beams of a supporting structure, such as a roof framework; arranging an elongate second portion of the elongate mounting member adjacent to and in general alignment with, but axially offset from, the first portion; and securely interconnecting the first portion and the second portion of the mounting member, whereby a longitudinal axis of the second portion is displaced or offset relative to a longitudinal axis of the first portion.
PCT/EP2009/003616 2009-05-20 2009-05-20 Mounting system for solar panels and connecting bracket for same WO2010133242A1 (en)

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Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
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Publication number Priority date Publication date Assignee Title
ITVR20120032A1 (en) * 2012-02-23 2013-08-24 Zintek S R L Unipersonale CONNECTOR FOR A SOLAR PANEL ON A BUILDING CLADDING.
US9147986B2 (en) 2012-12-20 2015-09-29 Mounting Systems Gmbh Fastening system for mounting solar modules
JP2016065396A (en) * 2014-09-25 2016-04-28 パナソニックＩｐマネジメント株式会社 Photovoltaic power generation device
WO2017145500A1 (en) * 2016-02-26 2017-08-31 パナソニックＩｐマネジメント株式会社 Solar photovoltaic device
NL2031243B1 (en) * 2022-03-10 2023-09-20 Tinteq Holding B V Mounting unit for solar panels

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JP2002030774A (en) * 2000-07-17 2002-01-31 Sekisui Chem Co Ltd Car port equipped with solar energy generator
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JP2000179106A (en) * 1998-12-18 2000-06-27 Hideo Fujita Device for attaching panel-shaped structure to outside enclosure
DE10125773A1 (en) * 2000-05-30 2001-12-06 Kurt Schade Gmbh & Co Ing Set of structural members for installing photovoltaic solar modules or water-carrying thermo-modules on inclined roof includes support section, holder and covering members
JP2002030774A (en) * 2000-07-17 2002-01-31 Sekisui Chem Co Ltd Car port equipped with solar energy generator
US20040216399A1 (en) * 2003-01-30 2004-11-04 Kyocera Corporation Fixing apparatus
WO2006072230A1 (en) * 2005-01-10 2006-07-13 Conergy Ag Threaded slider mounting system
DE202007003060U1 (en) * 2007-03-02 2008-07-17 SCHÜCO International KG connecting element
EP2146160A1 (en) * 2008-07-14 2010-01-20 Ubbink B.V. Sloped roof provided with a solar panel holder with extendible supporting rails

Cited By (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
ITVR20120032A1 (en) * 2012-02-23 2013-08-24 Zintek S R L Unipersonale CONNECTOR FOR A SOLAR PANEL ON A BUILDING CLADDING.
US9147986B2 (en) 2012-12-20 2015-09-29 Mounting Systems Gmbh Fastening system for mounting solar modules
US9638223B2 (en) 2012-12-20 2017-05-02 Mounting Systems Gmbh Fastening system for mounting solar modules
JP2016065396A (en) * 2014-09-25 2016-04-28 パナソニックＩｐマネジメント株式会社 Photovoltaic power generation device
WO2017145500A1 (en) * 2016-02-26 2017-08-31 パナソニックＩｐマネジメント株式会社 Solar photovoltaic device
NL2031243B1 (en) * 2022-03-10 2023-09-20 Tinteq Holding B V Mounting unit for solar panels
EP4312362A1 (en) * 2022-03-10 2024-01-31 Tinteq Holding B.V. Mounting unit for solar panels

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