WO2023214296A1

WO2023214296A1 - Mounting system

Info

Publication number: WO2023214296A1
Application number: PCT/IB2023/054539
Authority: WO
Inventors: Adrianus Franciscus Gerardus SCHUURMAN; Jacobus Jan SCHUURMAN
Original assignee: Schuurman Beheer B.V.
Priority date: 2022-05-02
Filing date: 2023-05-02
Publication date: 2023-11-09
Also published as: NL2034747B1; NL2031760B1

Abstract

A mounting system for superficial mounting of a device on a flat surface, particularly a roof surface, comprises a series of mounting bases (10,40) which each comprise a first mounting part (11) with a flexible overlay (40) whereby the relevant mounting base can be adhered to the roof surface (3). The system provides an elongate mounting rail (30) which extends over at least a number of the mounting bases (10,15,40). A second mounting part (12) of a mounting base provides a mounting face (15). Provided are fastening devices (20) whereby the mounting rail (30) is in each case connected or at least connectable clear of the roof surface (3) to the mounting face 15 of the second mounting part of a mounting base. The mounting rail provides fastening means for a durable fastening of the device.

Description

Mounting system

The present invention relates to a mounting system for superficial mounting of a number of spatially separated devices on a flat surface, particularly a roof surface, comprising a series of mounting bases which each comprise a first mounting part with a flexible overlay, whereby the relevant mounting base can be adhered to the roof surface, as well as a second mounting part on which is mountable an elongate mounting rail which extends over at least a number of the mounting bases, wherein fastening means are provided for durable fastening of at least a part of the number of devices to the mounting rail.

The ever increasing demand for sustainable energy sources has made photovoltaic conversion panels, usually referred to as solar panels, an indispensable option. The many roofs in our country are particularly suitable for installation of solar panels, with which electricity can be generated directly from sunlight. An important role is here played by flat roofs which are usually provided with a bitumen roof covering or other type of watertight sheet. For the purpose of arranging solar panels thereon a mounting system is preferably sought which leaves the integrity and particularly the watertightness of such an existing roof covering intact.

An existing mounting system which was designed for this purpose is described in Netherlands patent application NL 2028738 by applicant. Described herein is a mounting device in the form of a form-retaining dish with an overlay of a sheet of a roof covering material with which the dish can be adhered superficially to the existing roof covering. A threaded end, onto which a device such as a solar panel can be fastened, extends from the dish.

Although this known mounting device has proven itself as individual anchoring point in practice, it requires an accurate mutual alignment and a relatively great deal of working time if a solar farm with a large number of solar panels must be mounted thereby.

The present invention has for its object, among others, to provide a mounting system which also provides a solution in such a case by allowing a considerable tolerance in respect of the positioning of the individual anchoring points.

In order to achieve the stated object a mounting system of the type described in the preamble has the feature according to the invention that the second mounting part of the mounting bases provides at a distance from the flat surface a mounting face having transversely of a longitudinal direction of the mounting rail a width which is greater than a width of the mounting rail, and that fastening devices are provided whereby the mounting rail is in each case connected or at least connectable spatially separated from the flat surface to the mounting face of the second mounting part.

A mounting base thus provides not only a local anchoring point but an excessively dimensioned mounting face with a length and width which the fastening device is freely placeable on and connectable to with a certain tolerance. These larger dimensions, and thereby freedom of placing of the fastening device, in turn allow a tolerance in the mutual alignment of the mounting bases so that the mounting rail is nevertheless ultimately always connectable thereto by means of the fastening device provided for this purpose and adapted thereto. This fastening by means of the fastening device lies spatially separated, i.e. at a distance from, the flat surface on which the devices are placed so that an integrity of the flat surface, particularly in respect of watertightness, is left unaffected thereby.

In the case of an alignment of the mounting bases this relates particularly to a tolerance in the width direction. Because the relevant mounting face is always wider in the width direction than the mounting rail itself, it provides a freedom of placing for the mounting rail whereby any lack of mutual alignment of successive mounting bases can be accommodated without problem. The mounting system according to the invention is therefore particularly characterized in that at least a part of the mounting bases are mutually out of line in longitudinal direction, while the fastening devices thereof are aligned. With a view thereto, the mounting face is preferably significantly wider than the mounting rail, for instance a minimum of twice as wide, more particularly a minimum of four to five times wider or even a minimum of ten times wider.

A particular embodiment of the mounting system has the feature according to the invention that the fastening devices comprise in each case a mounting bracket under which the mounting rail is receivable, which mounting bracket is connected or is at least connectable durably to the mounting face of the second mounting part of a mounting base, particularly by means of screws or blind rivets. The mounting bases are for instance first placed on the flat surface and adhered thereto without penetrating the flat surface, in order to thus leave the existing roof covering intact. The mounting rail can then be placed thereon and anchored thereto by arranging in each case a mounting bracket at the appropriate position and securing it, clear of the flat roof, to the mounting face of a mounting base, particularly by screwing or nailing therein, without any covering of the flat roof being affected thereby.

A preferred embodiment of the mounting system is characterized according to the invention in that the mounting bracket comprises on one side proximally a flat base and lies against or is at least placeable on the mounting face of the second mounting part of the mounting base therewith, and that the mounting bracket comprises on the other side distally a hook-shaped outer end with an internal contour which connects to an external contour of the mounting rail. The mounting rail is thus receivable in closefitting manner under the hook-shaped outer ends of successive mounting brackets. The mounting rail can thus particularly be clamped fittingly under the mounting brackets and mutual play between the different parts can be eliminated.

A particularly practical embodiment of the mounting system has the feature here that the mounting bracket comprises at least substantially one integrally formed formretaining body, particularly a metal body, more particularly a body of aluminium, zincmagnesium-coated steel, stainless steel or otherwise preserved steel, and engages with a distal outer end round the mounting rail.

In a further particular embodiment the mounting system has the feature according to the invention that the first mounting part and the second mounting part of a mounting base are provided by an at least substantially integrally formed, joint form-retaining body, particularly a metal body, more particularly a body of aluminium, zincmagnesium-coated steel, stainless steel or otherwise preserved steel.

A preferred embodiment of the mounting system has the feature here according to the invention that the mounting bases each comprise an at least substantially dish-shaped body with an at least substantially flat edge part outside a central part which lies raised relative thereto, which edge part comprises the first connecting part and is intended and configured to lie flat against the flat surface, and which central part forms the second connecting part and provides the mounting face at a distance from the flat surface. The space under the mounting face toward the flat surface allows an outer end of a fastening member such as a screw or blind rivet, also referred to as pop rivet, blind pop rivet or rivet, to be received there with a certain tolerance without it coming into contact with, let alone penetrating, the flat surface. A distance of several millimetres to several centimetres will already suffice for this purpose.

In a further particular embodiment the mounting system has the feature according to the invention that the overlay comprises a flexible plastic flap which extends laterally outside the first mounting part of the mounting base yet is connected or is at least connectable firmly to the first mounting part, particularly by adhesion, particularly a flexible plastic flap of a flexible roof covering material. The plastic is here preferably compatible with a plastic covering which may be present on the flat roof. Adapting the choice of flexible flap thereto enables a highly reliable mutual adhesion to be brought about by welding (fusing) or glueing. In this respect the flap will in practice usually be formed particularly from bitumen (reinforced with a webbing), polyvinyl chloride (PVC) or ethylene propylene diene monomer (EPDM). A further preferred embodiment of the mounting system has the feature according to the invention that the mounting rail comprises an at least substantially linear profile with upright walls and a roof which mutually connects the walls while enclosing a body cavity running axially throughout the profile, and that the roof is provided with a pattern of carriage openings which expose the body cavity and in which carriage bolts are receivable, which carriage bolts form part of the fastening means for durable fastening of a device. A particular embodiment of the mounting system according to the invention has the feature here that the profile comprises an extrusion profile, particularly of metal, more particularly of aluminium, stainless steel, zinc-magnesium- coated steel or otherwise preserved steel.

A carriage opening is here understood to mean an elongate opening behind which a carriage bolt with a substantially correspondingly shaped head anchors by a rotation thereof through a quarter turn. By tightening a nut screwed thereon, this state can be utilized in particularly practical and rapid manner for firm fastening of a device. Ideally, the fastening devices leave the carriage openings in the mounting rail clear. A further preferred embodiment of the mounting system has for this purpose the feature according to the invention that the fastening devices comprise in each case a mounting bracket under which the mounting rail is receivable, which mounting bracket is on one side connected or at least connectable durably to the second mounting part of the mounting base, and on the other side engages with a distal part round the mounting rail, wherein the mounting bracket is provided in the distal part with an opening which leaves the carriage opening in the mounting rail clear, particularly with an axially running slotted opening extending over a pitch between the carriage opening and a subsequent carriage opening in the mounting rail.

The invention also relates to a mounting rail, mounting base and/or fastening device for application in the above described mounting system according to the invention and will be further elucidated hereinbelow with reference to an exemplary embodiment and an accompanying drawing. In the drawing:

Figure 1 A is a top view of a mounting base in an exemplary embodiment of the mounting system according to the invention;

Figure 1 B is a section of the mounting base of figure 1A along the line B-B;

Figure 1C is a section of the mounting base of figure 1A along the line C-C;

Figure 2A is a top view of a mounting bracket of the exemplary embodiment of the mounting system according to the invention;

Figure 2B is a section of the mounting bracket of figure 2A along the line B-B;

Figure 3A is a top view of a mounting rail of the exemplary embodiment of the mounting system according to the invention;

Figure 3B is a cross-section of the mounting rail of figure 3A along the line B-B;

Figure 4 is a top view of a flexible overlay for mounting the mounting base of figures 1A-1C;

Figure 5 is a cross-section of the mounting system according to the invention in assembled state;

Figure 5A is an enlarged detail of the cross-section of figure 5; and

Figure 6 is a top view of the mounting system of figure 5. It is otherwise noted here that the figures are purely schematic and not always drawn to (the same) scale. Some dimensions in particular may be exaggerated to greater or lesser extent for the sake of clarity. Corresponding parts are designated in the figures with the same reference numeral.

An exemplary embodiment of a mounting system according to the invention is based on a series of mounting bases, an exemplary embodiment of which is shown in top view and in respective orthogonal cross-sections in figures 1A-1G Each mounting base 10 comprises a first mounting part 11 whereby the mounting base 10 in question can be mounted superficially on a (roof) surface 3. Use can be made for this purpose of the overlay 40, which is shown in figure 4 and will be elucidated below, so that an underlying (roof) surface is prevented from being pierced or otherwise affected. Each mounting base 10 additionally comprises a second mounting part 12 which lies at a somewhat raised position relative to the first mounting part 11. This second mounting part 12 provides a mounting base 15 which will thereby lie at a certain distance w from the underlying (roof) surface, see also figure 5A.

In this embodiment use is made for the mounting base 10 of a monolithic metal body which was deep-drawn integrally from a plate body. In this embodiment use was made for this purpose of a plate body of stainless steel with a thickness of 2 millimetres, although it is instead also possible to opt for a different thickness and/or to make use of a different material such as for instance aluminium, zinc-magnesium-coated steel or otherwise preserved steel. The thus formed mounting base 10 thus comprises a dishshaped central part in which lies the second mounting part 12 with mounting face 15, this being surrounded by a flat, flange-shaped edge part which forms the first mounting part. The central part 12 lies raised relative to edge part 11 over a distance w of about 15 millimetres, as shown in the orthogonal sections of figures 1 B and 1C.

The mounting face 15 thus maintains said distance w to a surface 3 which lies thereunder and on which the system will be mounted. This mounting face 15 provides spatially separated from the underlying (roof) surface 3 a mounting base for an elongate mounting rail 30, see figures 3A and 3B, which can in each case be fixed in the manner to be elucidated below onto such a mounting base 10 of a series of mounting bases without touching the (roof) surface 3 by means of fastening devices 20 provided for this purpose, see figures 2A and 2B. This particularly eliminates the danger of the (roof) surface being penetrated, which could otherwise result in a leak.

In this example use is made for the fastening devices of mounting brackets 20, one of which is shown in top view in figure 2A and in cross-section in figure 2B. The bracket 20 is formed integrally from a folded plate body for which use is here also made of stainless steel with a thickness of 2 millimetres because of the corrosion resistance and strength of this material, although it is here also possible instead to opt for a different thickness and/or to make use of a different material such as for instance aluminium, zinc-magnesium-coated steel or otherwise preserved steel. The bracket 20 comprises on one side a flat base 21 with which the bracket can be mounted on the mounting face 15 of mounting base 10. With a view thereto a set of screw openings 24 is provided in this part, although use can also be made for this purpose of self-tapping screws (P-K screws). On the other side the bracket 20 comprises a hook-shaped distal outer end 23 whereby the bracket engages fittingly round the mounting rail 30 shown in figure 3. Provided herein is an elongate slotted opening 25 which will in each case leave clear at least one carriage opening 35 in mounting rail 30. The flat base 21 and the distal outer end 23 are mutually connected via an oblique flank 22 which bridges a distance between the flat base 21 and the roof 31 of mounting rail 30.

The mounting rail 30 of the mounting system is shown in further detail in figures 3A and 3B in respectively top view and cross-section. Mounting rail 30 is formed by an elongate, linear extrusion profile 30, for instance, as in this embodiment, of aluminium, with a roof 31 which is flanked by a set of upright walls 32, 33. The roof 31 and walls 32, 33 bound a body cavity 34 which extends axially in profile 30. Profile 30 has a wall thickness of 2 to 3 millimetres and has a length in the order of several metres to several tens of metres. Formed in the roof is a series of carriage openings 35 in which carriage bolts 37 are receivable with a head adapted thereto, this head being longer than a width of a carriage opening 35 and shorter than a length thereof. Such a carriage bolt 37 can thus be inserted with the head into a carriage opening 35 and be anchored therebehind by a quarter turn in simple manner. In combination with a nut fitting thereon, this provides a practical mounting option on a flat roof 3, particularly a roof surface, for a device of a system of devices, such as solar panels, to be fixed on mounting rail 30.

For superficial mounting of a mounting base 10 the mounting system provides a flexible overlay such as for instance the plastic rosette 40 shown in figure 4. The rosette is formed from a flexible flap of roof covering material, such as EPDM, PVC or bitumen, depending on the roof covering layer which may already be present on the (roof) surface 3. The rosette comprises centrally a recess 45 the size of the central second mounting part 12 with the mounting face 15 of mounting base 10 so that this will eventually remain clear and accessible inside the rosette 40, see also figure 5. In this embodiment use is made for rosette 40 of a flexible bitumen bib reinforced with a standard webbing.

In order to mount a device such as solar panel of a system of solar panels, a so-called solar farm, on a flat roof such as a roof surface a series of mounting bases 10 are each mounted on roof surface 3 using such a rosette 40. For this purpose a rosette 40 of a plastic which provides a good adhesion with the existing roof covering is preferably opted for. This embodiment is based on a rosette of bitumen and roof covering of the same. By heating both the existing roof covering of this or similar material on substrate 3 and an underside of rosette 40 a particularly strong adhesion can be achieved of both slightly fluid bitumen layers to each other and to the intermediate first mounting part 11 of mounting base 10. This adhesion is contributed to by the openings and recesses provided for this purpose in this part 11 of the relevant mounting base 10, see figure 1A, in that they allow direct bitumen-bitumen contact there. A sufficient number of mounting bases 10 is in this way adhered to roof surface 3 and here roughly aligned relative to each other.

Mounting rail 30 is then laid out over the mounting faces 15 of mounting bases 10, 40 and fixed to each of the mounting bases with a mounting bracket 20. The bracket is for this purpose placed with the distal outer end 23 round profile 30 and screwed fixedly onto mounting face 15 by means of a set of self-tapping screws 27. The cavity under the dish-like mounting face 15 provides for the distance w relative to the substrate 3 so that a screw 27 is here prevented from coming up against, let alone penetrating, roof surface 3, see also figure 5A. The thus fastened mounting rail 30 is shown in top view in figure 6. This shows that the slotted opening 25 in mounting bracket 20 leaves clear a carriage opening 35 in profile 30 so that at least one carriage opening 35 will always be available for firm fastening of a device.

Although the mounting rail 30 provides for an independent alignment of the mounting system, on which a reliable and durable fastening of a device such as a system of solar panels is mountable at the appropriate position, this need not be the case, at least not to the same extent, for a mutual alignment of the mounting bases 10. According to the invention, the mounting face 15 thereof namely has transversely of a longitudinal direction of mounting rail 30 a width b1 which is considerably greater than a corresponding width b of mounting rail 30 itself. In this embodiment the mounting surface 15 as mounted in figure 6 is even in the order of ten times wider than mounting rail 30. With interposing of mounting brackets 20 the mounting rail 30 can hereby in each case be screwed fixedly onto a mounting face 15 of an individual mounting base with a wide tolerance without coming into contact with roof surface 3 and without mounting bases 10 having to be precisely aligned with each other for this purpose. This makes the mounting system according to the invention particularly practical, particularly if a system of a large number of devices must thereby be arranged on a roof surface in a regular array over a great length and width. In the longitudinal direction the mounting surface 15 also has a width b2 which is about four times greater than the width b of mounting rail 30, so that the mounting bases can also be applied at a modified angle, even as far as transversely of the shown device, while preserving these advantages. Although the invention has been further elucidated above with reference to only a single exemplary embodiment, it will be apparent that the invention is by no means limited thereto. On the contrary, many variations and embodiments are still possible within the scope of the invention for a person with ordinary skill in the art

Claims

Claims:

1. Mounting system for superficial mounting of a number of spatially separated devices on a flat surface, particularly a roof surface, comprising a series of mounting bases which each comprise a first mounting part with a flexible overlay, whereby the relevant mounting base can be adhered to the roof surface, as well as a second mounting part on which is mountable an elongate mounting rail which extends over at least a number of the mounting bases, wherein fastening means are provided for durable fastening of at least a part of the number of devices on the mounting rail, characterized in that the second mounting part of the mounting bases provides at a distance from the flat surface a mounting face having transversely of a longitudinal direction of the mounting rail a width which is greater than a width of the mounting rail, and that fastening devices are provided whereby the mounting rail is in each case connected or at least connectable spatially separated from the flat surface to the mounting face of the second mounting part.

2. Mounting system according to claim 1, characterized in that at least a part of the mounting bases are mutually out of line in longitudinal direction, while the fastening devices thereof are aligned.

3. Mounting system according to claim 1 or 2, characterized in that the fastening devices comprise in each case a mounting bracket under which the mounting rail is receivable, which mounting bracket is connected or is at least connectable durably to the mounting face of the second mounting part of a mounting base, particularly by means of screws or blind rivets.

4. Mounting system according to claim 3, characterized in that the mounting bracket comprises on one side proximally a flat base and lies against or is at least placeable on the mounting face of the second mounting part of the mounting base therewith, and that the mounting bracket comprises on the other side distally a hookshaped outer end with an internal contour which connects to an external contour of the mounting rail.

5. Mounting system according to claim 3 or 4, characterized in that the mounting bracket comprises at least substantially one integrally formed form-retaining body, particularly a metal body, more particularly a body of aluminium, zinc-magnesium- coated steel, stainless steel or otherwise preserved steel, and engages with a distal outer end round the mounting rail.

6. Mounting system according to one or more of the preceding claims, characterized in that the first mounting part and the second mounting part of a mounting base are provided by an at least substantially integrally formed, joint formretaining body, particularly a metal body, more particularly a body of aluminium, zincmagnesium-coated steel, stainless steel or otherwise preserved steel.

7. Mounting system according to one or more of the preceding claims, characterized in that the mounting bases each comprise an at least substantially dish- shaped body with an at least substantially flat edge part outside a central part which lies raised relative thereto, which edge part comprises the first connecting part and is intended and configured to lie flat against the flat surface, and which central part forms the second connecting part and provides the mounting face at a distance from the flat surface.

8. Mounting system according to one or more of the preceding claims, characterized in that the overlay comprises a flexible plastic flap which extends laterally outside the first mounting part of the mounting base yet is connected or is at least connectable firmly to the first mounting part, particularly by adhesion, particularly a flexible plastic flap of a flexible roof covering material, such as bitumen, polyvinyl chloride (PVC) or ethylene propylene diene monomer (EPDM).

9. Mounting system according to one or more of the preceding claims, characterized in that the mounting rail comprises an at least substantially linear profile with upright walls and a roof which mutually connects the walls while enclosing a body cavity running axially throughout the profile, and that the roof is provided with a pattern of carriage openings which expose the body cavity and in which carriage bolts are receivable, which carriage bolts form part of the fastening means for durable fastening of a device.

10. Mounting system according to claim 9, characterized in that the profile comprises an extrusion profile, particularly of metal, more particularly of aluminium, zinc-magnesium-coated steel, stainless steel or otherwise preserved steel.

11. Mounting system according to claim 9 or 10, characterized in that the fastening devices comprise in each case a mounting bracket under which the mounting rail is receivable, which mounting bracket is on one side connected or at least connectable durably to the second mounting part of the mounting base, and on the other side engages with a distal part round the mounting rail, wherein the mounting bracket is provided in the distal part with an opening which leaves the carriage opening in the mounting rail clear, particularly with an axially running slotted opening extending over a pitch between the carriage opening and a subsequent carriage opening in the mounting rail.

12. Mounting rail, mounting base and/or fastening device for application in the mounting system according to one or more of the preceding claims.