Description:FIELD OF THE INVENTION
Present invention relates to the field of modular frame configuration for securely holding and attaching the solar modules to a mounting structure. Present invention more particularly relates to an extruded profile with back cleat clips for holding and mounting of solar modules on the mounting structures in which the back cleat clips assembled with the main frame made up of an extruded profile of aluminium material by press fitting at required location is used.
In the proposed extruded profile with back cleat clips, thickness dimension of the cleat clip can be varied as per requirement without changing design and hence weight of the main frame. Proposed extruded profile with back cleat clips is (i) having better mechanical strength, (ii) having better module load bearing capacity, (iii) having prolonged life span matching with life span of solar modules, (iv) light in weight, (iv) with flexibility to assembled back cleat clips at required location as per mounting hole positions on the mounting structure, (v) easy to manufacture and (vi) economic. It eliminates or minimizes chances of damage of the solar modules due to dynamic loading because of wind load by firmly holding it on the mounting structure.
Proposed frame made up of an extruded profile with back cleat clips is designed for mounting of solar modules in residential, commercial and utility scale ground mount solar systems.
BACKGROUND OF THE INVENTION
In just one hour, the sun provides enough energy to power the entire world for a year. The potential of solar energy is nearly boundless as it is a fully renewable resource that doesn't rely on any fuel for its generation. Consequently, the photovoltaic (PV) industry is becoming increasingly crucial in addressing the global energy demands.
Solar modules also known as Photovoltaic (PV) modules are devices that convert sunlight directly into electricity. They are composed of multiple interconnected solar cells made from semiconductor materials, typically silicon. When sunlight hits these cells, it generates an electric current. Solar modules are a fundamental component of solar power systems and are used in a variety of applications, from residential and commercial solar panel installations to large-scale solar farms.
The mounting and frame design of solar modules is crucial for several reasons and deserves careful consideration:
• From structural integrity and safety point of view, proper mounting and sturdy frames ensure that solar modules are securely attached to their supporting structures, which is essential to withstand various environmental conditions such as wind, rain, and snow. This helps prevent damage to the modules and reduces the risk of accidents.
• The design and orientation of the mounting system can significantly affect the performance of solar modules. Properly angled and positioned mounts maximize exposure to sunlight, thereby enhancing the efficiency of energy conversion.
• Innovative mounting and frame designs can simplify the installation process, reducing labor time and costs. Easier installation can also lower the overall cost of solar energy projects. Additionally, well-designed systems facilitate easier maintenance and access for repairs or cleaning, prolonging the lifespan of the solar modules.
• The appearance of photovoltaic (PV) installations can be important, especially in residential or commercial settings. Sleek, frameless designs or modules with aesthetically pleasing frames can blend better with the architecture of buildings and improve visual appeal.
• Advances in mounting and frame designs can lead to cost reductions. For example, lightweight and modular frames can reduce transportation and installation costs. Efficient designs that require fewer materials can also contribute to overall savings.
• High-quality mounting systems and frames protect solar modules from environmental stressors and physical damage, ensuring long-term durability and reliable performance over the modules' expected lifespan.
• Flexible mounting systems can be adapted to various surfaces and environments, including rooftops, open fields, or even water bodies (in the case of floating solar farms). This versatility allows for broader application of solar technology.
Given these factors, the design of mounting systems and frames is a critical aspect of solar module deployment that impacts the overall success and sustainability of solar energy projects.
There are various designs and mounting systems available for solar modules. Traditionally, solar modules have been mounted in aluminium frames to be securely attached to the supporting structure. To reduce costs, simplify installation, and enhance the aesthetics of solar modules, new frame designs and frameless designs are continuously being developed. A common aspect of many of these innovative systems is the need for structural bonding to attach glass or other materials to the supporting structure, such as a frame, rail, or pad.
Currently, frames are typically made from materials such as aluminium alloy, steel, plastic, or polymers like polyvinyl chloride (PVC). Silicon sealant is applied in the sections of the frame to ensure adhesion and watertightness once it cures (hardens).
There are various framing systems available to securely attach solar modules to a supporting structure. While the provided illustrations serve as examples, numerous other designs and configurations are possible. Each frame design must be validated by module manufacturers through appropriate technical qualification tests.
Clamping is the most significant external factor responsible for the breakage of glass in frameless photovoltaic (PV) modules. Glass/glass modules are particularly sensitive to glass breakage. Failure can occur either during the installation of the PV modules or while they are in service. Contributing factors to such failures include: Poor Geometrical Design of Clamps: clamps with sharp edges, and those that are too short or too narrow, can cause damage; Improper Clamp Positioning: incorrect placement of clamps on the module can lead to stress and breakage; Excessive Clamping Pressure: applying too much pressure during the mounting phase can damage the glass; Wind Load Stress: material failure due to wind loads acting on the PV module; Material Failure: failure of the module or frame material, including the mounting frame, due to environmental effects and; Clam loosening Over Time: clamps used for mounting the PV modules can loosen over time, leading to instability and potential breakage.
DESCRIPTION OF THE RELATED ART
The invention and development of various frame designs have evolved to mount solar modules, addressing one or more challenges faced by the industry.
The development of frame designs aimed at enhancing flexibility during the installation of photovoltaic modules has been addressed. Indian patent application number 118/DELNP/2010 introduces a solar module featuring a frame designed for mounting onto a structure capable of withstanding wind and snow loading without compromising its integrity or adding significant mass compared to conventional frames. Additionally, this innovation allows for flexibility during installation, accommodating irregularities in the structure without requiring additional holes to be drilled into the frame.
Various frame designs utilizing different profiles and materials such as aluminium and steel for mounting photovoltaic (PV) modules have been reported. Indian patent application number 3014/CHENP/2012 describes frames constructed using extruded profile members of aluminium alloys surrounding the solar panels. Utility patent number CN217789623U presents a support frame for solar PV panels, comprising a steel frame buckled by a thin-walled steel plate to ensure high strength and minimal deformation, creating a regular accommodating cavity for easy installation of corner connectors. Utility patent number CN219107373U introduces an aluminium profile for a solar PV panel frame, incorporating a reinforcing long strip block to enhance the frame's overall strength, prolonging its service life and reducing safety risks and costs. Patent number DE19700873A1 discloses a solar collector frame consisting of an S-shaped profile for fastening solar modules and panels onto a pad using two Chen U-shaped profiles arranged one above the other and on opposite sides.
Specific frame designs for mounting photovoltaic (PV) modules are tailored to meet particular requirements. Patent number EP1860705A1 describes a solar cell module and solar cell array featuring a notch with a predetermined opening width on the upper surface (light receiving surface) of the module frame. This notch enhances drainage of the light receiving surface, improving overall efficiency. Indian patent application number 202311017890 introduces a solar panel frame that overlaps with an adjoining frame of a second solar panel, requiring fewer fasteners compared to conventional frame structures. This design reduces installation complexity and enhances structural integrity. Indian patent application number 202341074683 presents frames designed to incorporate solar panels directly into roofing structures, allowing the panels to serve as the roof itself. This innovative design integrates solar energy generation seamlessly into building structures, maximizing space utilization and energy efficiency.
FIG. 1 shows most common design of a frame (1) used for mounting of solar modules used in industry. The frame (1) as per FIG. 1 is made up of an extruded aluminium profile (2). It is mounted on a mounting structure using a mounting bolt (3).
The frame as per FIG. 1 which is made from single material with a major focus on aesthetic feature is suffering from certain common drawbacks. The frame as per FIG. 1 is with lower mechanical load bearing capacity. Weight of aluminium required for the frame is 5.45 gram per Watt. As production of one ton of aluminium adds 4.80 tons CO2 to atmosphere, higher aluminium requirement means higher carbon footprint. Maximum mechanical structural load of 2400 Pa can be applied to existing aluminium frame and results in 866 MPa loading on the frame. Numerous frame fatigue issues and solar module damage issues are reported so far in field deployment. The existing aluminium frame as per FIG. 1 consist of predefined fixed mounting holes and are suitable for only one kind of mounting system. Less solar glass area can rest on existing aluminium frame as per FIG. 1 resulting in less strength.
OBJECT OF THE INVENTION
Principal object of the present invention is to provide a frame for supporting and holding the solar modules.
Further object of the present invention is to provide a frame for supporting and holding the solar modules that is modular in design involving two different components.
Further object of the present invention is to provide a frame for supporting and holding the solar modules that provides larger supporting surface area for the solar modules for better stability.
Further object of the present invention is to provide a frame for supporting and holding the solar modules that can withstand higher snow and wind loading.
Further object of the present invention is to provide a frame for supporting and holding the solar modules that reduces an overall weight of aluminium material per KW of installed capacity of photovoltaic system.
Further object of the present invention is to provide a frame for supporting and holding the solar modules that made up of a main frame provided with back cleat clips assembled with the main frame at appropriate location as per position of the mounting holes provided in the mounting structure.
Further object of the present invention is to provide a frame for supporting and holding the solar modules that that is provided with back cleat clips for which thickness dimension can be varied as per requirements for better strength.
Further object of the present invention is to provide a frame for supporting and holding the solar modules that allows use of the main frame with lower uniform thickness and thereby reducing overall weight of the frame.
Further object of the present invention is to provide a frame for supporting and holding the solar modules that uniformly distribute clamping load only on the back cleat clips while uniformly transferring service load on the main frame cross-section and thereby preventing failure of the solar modules and the main frame because of clamping force.
Further object of the present invention is to provide a frame for supporting and holding the solar modules that is having better corrosion resistance because of absence of weld joints.
Further object of the present invention is to provide a frame for supporting and holding the solar modules that is having prolonged life of 27-30 years.
The aluminium frames as per prior art used for mounting of photovoltaic (PV) module in practice have fatigue and fracture problems due to excessive vibration in case of high wind and snow loading specifically in harsh weather conditions. In such events, the solar modules get damaged, frame gets damaged, solar modules get ripped off from the mounting structure etc. All of these require replacement of affected solar modules and or frames in the fields and cause huge loss to the solar modules manufacturer and the photovoltaic (PV) plant owner.
The proposed frame for supporting and mounting of solar modules is consisting of a main frame made up of an extruded profile for supporting and holding solar module and back cleat clips assembled with the main frame.
SUMMARY OF THE INVENTION
Present invention relates to a modular frame for mounting of solar modules in photovoltaic (PV) systems in which a mainframe made up of an extruded profile of aluminium material with back cleat clips made up of an aluminium material assembled to it.
Proposed extruded profile with back cleat clip for mounting of solar modules is consisting of a main frame for supporting and holding solar module and; back cleat clips assembled with the main frame.
The proposed main frame is provided with a solar module gripping profile, a main frame locking profile positioned adjacent to the solar module gripping profile and a back cleat clip fixing profile positioned adjacent to the main frame locking profile. The solar module gripping profile is configured to support and firmly grip the solar modules by its elastic deformation followed by application of sealant at interface of the upper projected profile and solar module and, the support surface and the solar module. The main frame locking profile is configured for mechanically assembling short and long frame with each other, for increasing stiffness of the main frame wherein the main frame assembled with width and length of the solar module is named as short and long main frame respectively.
The back cleat clip fixing profile is configured for mechanically assembling and griping the back cleat clips at required longitudinal location by press fitting the back cleat clips followed by plastic deformation of the back cleat clip fixing profile corresponding to length of the back cleat clip by punching.
Cross-section dimension of the back cleat clips can be varied as per requirement without changing designed thickness of the main frame resulting into overall reduction in the weight of the extruded profile with the back cleat clips.
As clamping of the extruded profile with back cleat clip holding solar modules with the mounting structure is done by fastening using the back cleat clips, clamping forces and hence related stresses are acting only on the back cleat clips preventing failure of the main frame due to clamping forces.
In proposed design, maximum stress generated in the main frame material is reduced drastically. The modular frame prevents loosening of the fasteners and resulting vibrations due to dynamic service loads acting on the modular frame because of use of the back cleat clips. The modular frame is having improved life span with more uniform stress distribution in the material of the main frame and especially suitable for upcoming bigger photovoltaic (PV) modules (e.g. 700 Wp).
BRIEF DESCRIPTION OF THE DRAWINGS
The features of the invention as per the present patent application are described with reference to the following drawings in which like elements are labeled similarly. The present invention will be more clearly understood from the detailed description and the accompanying drawings, wherein:
FIG. 1 is a schematic diagram showing most common design of a frame (1) made up of an extruded aluminium profile (2) for manufacturing and mounting of solar modules as per prior art.
FIG. 2 is a schematic diagram showing cross sectional view of an assembly of a back cleat clip (201) with a main frame (101) and mounting of a solar panel (301) on a mounting structure (401) as per present invention.
FIG. 3 is a schematic diagram showing a main frame (101) of an extruded profile with back cleat clip for the solar modules manufacturing and mounting as per present invention.
FIG. 4 is a schematic diagram showing a back cleat clip (201) of an extruded profile with back cleat clip for the solar modules manufacturing and mounting as per present invention.
FIG. 5 is a schematic diagram showing various dimensions on a main frame (101) of an extruded profile with back cleat clip as per present invention.
FIG. 6 is a schematic diagram showing various dimensions on a back cleat clip (201) as per present invention.
FIG. 7 is a pictorial view of an assembly of a back cleat clip (201) with a main frame (101) as per present invention.
FIG. 8 (a-b) is photographs showing damage witnessed in the frame holding the photovoltaic (PV) module.
FIG. 9 (a-b) is photographs showing failure due to ripping off of the photovoltaic (PV) module from the mounting structure.
List of designations/ reference numbers in figure
1. a frame as per prior art
2. an extruded aluminium profile
3. a mounting bolt
100. an extruded profile with back cleat clip
101. a main frame
102. a support surface
103. an upper projected profile
104. a rectangular enclosed opening
105. a projected longitudinal rib
106. a rectangular enclosed opening formed by a back cleat clip fixing profile (1013)
107. a pair of longitudinal wedge shaped rib
108. a gap dimension formed by the pair of longitudinal wedge shaped rib (107)
109. a dimension of the back cleat clip fixing profile (1013) in assembled condition
110. a punching surface of the back cleat clip fixing profile (1013)
111. a back cleat clip insert opening
112. a gap dimension between the support surface (102) and the upper projected profile (103)
113. a thickness dimension of the upper projected profile (103)
114. an internal surface of the rectangular enclosed opening (104)
115. a vertical rib of a back cleat clip fixing profile (1013)
116. a taper surface of a longitudinal wedge shaped rib (107)
117. a vertical surface of a longitudinal wedge shaped rib (107)
118. an internal surface of a rectangular enclosed opening (106) formed by a back cleat clip fixing profile (1013)
119. a wall thickness of a back cleat clip fixing profile (1013)
120. an overall dimension of a main frame (101)
121. a distance between back cleat clip insert openings (111)
201. a back cleat clip
202. a back cleat clip positioning profile
203. a back cleat clip fixing profile
204. an L-shape bend
205. a back cleat clip clamping surface
206. a thickness dimension of the L-shaped bend (204) of a back cleat clip (201)
207. a thickness dimension a back cleat clip clamping surface (205) of a back cleat clip (201)
208. a length of fixing portion of a back cleat clip (201)
209. a dimension of the back cleat clip fixing profile (203)
210. an end of a wedge shape cross-section of a back cleat clip (201)
211. a neck
212. a minimum dimension of a wedge shape cross-section at an end (210)
213. a maximum dimension of a wedge shape cross-section at an end (214)
214. an end of a wedge shape cross-section of a back cleat clip (201)
215. a length of clamping surface (205) of a back cleat clip (201)
216. a through slot on a back cleat clip clamping surface (205)
301. a solar module
401. a frame structure
1011. a solar module gripping profile
1012 a main frame locking profile
1013. a back cleat clip fixing profile
DETAILED DESCRIPTION OF THE INVENTION
The following description of the preferred embodiment(s) is merely exemplary in nature and is in no way intended to limit the invention, its application, or its uses.
The description of illustrative embodiments according to principles of the present invention is intended to be read in connection with the accompanying drawings, which are to be considered as a part of the entire written description. In the description of embodiments of the invention disclosed herein, any reference to direction or orientation is merely intended for convenience of description and is not intended in any way to limit the scope of the present invention. Relative terms and directives thereof are for convenience of description only and do not require that the apparatus be constructed or operated in a particular manner unless explicitly indicated as such. Terms such as “attached,” “affixed,” “connected,” “coupled,” “interconnected,” and similar references to a relationship wherein structures are secured or attached either directly or indirectly through intervening structures, as well as both movable and rigid attachments or relationships, unless expressly described otherwise. Moreover, the features and benefits of the invention are illustrated by reference to the exemplified embodiments. Accordingly, the invention expressly should not be limited to such exemplary embodiments illustrating some possible non-limiting combination of features that may exist alone or in other combinations of features; the scope of the invention being defined by the claims appended hereto.
Present invention relates a frame for securely holding and attaching the solar modules to a mounting structure. Present invention relates to a modular frame for mounting of solar module in photovoltaic (PV) systems where the frame is consisting of an extruded profile with back cleat clips for holding and mounting of solar modules on the mounting structures in which the back cleat clips assembled with the main frame made up of an extruded profile of aluminium material by press fitting at required location is used.
As shown in FIG. 2, an extruded profile with back cleat clip (100) for mounting of solar modules (301) as per present invention is consisting of a main frame (101) for supporting and holding solar module (301) and; back cleat clips (201) assembled with the main frame (101) for fixing of the main frame (101) holding the solar modules (301) on a mounting structure (401).
FIG. 3 shows the main frame (101). As shown in FIG. 3, the main frame (101) is made up of a longitudinal extruded profile of aluminium material. As shown in FIG. 3 and FIG. 5, an extruded cross section profile of the main frame (101) is consisting of a solar module gripping profile (1011) used for gripping of the solar modules (301), a main frame locking profile (1012) positioned adjacent to the solar module gripping profile (1011) and used for assembling short and long main frames (101) with each other using a key partially inserted into the short and long main frames (101) to be assembled and, a back cleat clip fixing profile (1013) positioned adjacent to the main frame locking profile (1012) and used for assembling the back cleat clips (201) with the main frame (101). The main frame locking profile (1012) increases stiffness of the main frame (101). The main frame (101) assembled along the length and width of the solar module (301) is named as long and short main frames (101) respectively.
As shown in FIG. 3, the solar module gripping profile (1011) is consisting of a support surface (102) for resting the solar module (301) and an upper projected profile (103) extending from the support surface (102) for gripping the solar module (301) against the support surface (102).
As shown in FIG. 3 and FIG. 5, a gap dimension (112) between the support surface (102) and the upper projected profile (103) and a thickness dimension (113) of the upper projected profile (103) is maintained such that the upper projected profile (103) elastically deforms and firmly grips the solar module (301) resting on the support surface (102) as shown in FIG. 2. Sealant is applied after gripping the solar module (301) resting on the support surface (102) by the upper projected profile (103). The sealant is applied at interface of the upper projected profile (103) and solar module (301) and, the support surface (102) and the solar module (301),
As shown in FIG. 3 and FIG. 5, the main frame locking profile (1012) forms a rectangular enclosed opening (104). A pair of projected longitudinal ribs (105) is provided on an internal surface (114) of the rectangular enclosed opening (104) of the main frame locking profile (1012). These projected longitudinal ribs (105) are used for assembling the short and long main frame (101) with each other by using a key which is partially inserted into the short and long main frames (101) to be assembled. Outer dimensions of the key are provided such that it forms interference fit with the dimensions of the rectangular enclosed opening (104). This results into proper fitting of the short and long main frames (101) with each other. Such a feature increase overall stiffness of the extruded profile with back cleat clips (100) as per present invention.
As shown in FIG. 3 and FIG. 5, the back cleat clip fixing profile (1013) forms a rectangular enclosed opening (106). This rectangular enclosed opening (106) is provided with a pair of longitudinal wedge shaped rib (107) positioned opposite to each other on its internal surface (118). The back cleat clip fixing profile (1012) is used for assembling the back cleat clips (201) with the main frame (101). As shown in FIG. 3, back cleat clip insert openings (111) are cut on a vertical rib (115) of the back cleat clip fixing profile (1013). A distance (121) between these openings are maintained such that the back cleat clips (201) are assembled at required longitudinal position on the main frame (101) depending on the position of the clamping holes provided on the mounting structure (401). For assembling the back cleat clip (201) with the main frame (101), it is press fitted into the back cleat clip fixing profile (1012) of the main frame (101) by inserting it through back cleat clip insert openings (111). The cleat clip (201) is made up of an aluminium material.
As shown in FIG. 3 and FIG. 5, the pair of longitudinal wedge shaped rib (107) is provided with its taper surface (116) facing towards the vertical rib (115) on which the back cleat clip insert openings (111) are cut and its vertical surface (117) facing towards a vertical rib (118).
As shown in FIG. 4, the back cleat clip (201) is provided with a back cleat clip positioning profile (202) at its one end (210), a back cleat clip fixing profile (203) connected to the cleat positioning profile (202) using a neck (211), an L-shaped bend (204) provided adjacent to the back cleat clip fixing profile (203), a back cleat clip clamping surface (205) extending from the L-shaped bend (204) and, a through slot (216) on a back cleat clip clamping surface (205).
FIG. 6 shows a thickness dimension (206) of the L-shaped bend (204) and a thickness dimension (207) of the back cleat clip clamping surface (205) of the back cleat clip (201). The thickness dimensions (206, 207) of the L-shaped bend (204) and the back cleat clip clamping surface (205) respectively can be varied as per the requirement depending upon the static and dynamic load acting upon the solar module and clamping forces for clamping of the extruded profile with back cleat clip (100) holding the solar modules (301) without changing design of the main frame (101). This results into overall reduction in the weight of the extruded profile with back cleat clip (100).
As shown in FIG. 4 and FIG. 6, the back cleat clip positioning profile (202) is of a wedge shape cross-section. The back cleat clip positioning profile (202) is provided with minimum dimension (212) at the end (210) and maximum dimension (213) at another end (214). This wedge shape cross-section of the back cleat clip positioning profile (202) facilitates press fitting of the back cleat clip (201) into the back cleat clip fixing profile (1013) through the back cleat clip insert opening (111).
FIG. 5 shows, a gap dimension (108) formed by the pair of longitudinal wedge shaped rib (107). FIG. 6 shows the maximum dimension (213) provided at the end (214) of the back cleat clip positioning profile (202). The gap dimension (108) formed by the pair of longitudinal wedge shaped rib (107) is kept smaller than the maximum dimension (213) provided at the end (214) of the back cleat clip positioning profile (202). The gap dimension (108), the dimension (213) and a wall thickness (119) of the back cleat clip fixing profile (1013) is configured such that on press fitting the back cleat clip (201), the back cleat clip fixing profile (1013) deforms elastically resulting into increase in the gap dimension (108) allowing the back cleat clip positioning profile (202) to completely cross the longitudinal wedge shaped rib (107). On crossing of the a longitudinal wedge shaped rib (107) by the end (214) of the back cleat clip positioning profile (202), the back cleat clip fixing profile (1013) again regain its original size and shape locking the back cleat clip positioning profile (202) on left side of the longitudinal wedge shaped rib (107) in the back cleat clip fixing profile (1013). This calibrates the cross positioning of the back cleat clip (201) into the back cleat clip positioning profile (202).
FIG. 6 shows a dimension (209) of the back cleat clip fixing profile (203). As shown in FIG. 2, FIG. 5 and FIG. 6, in assembled condition, the dimension (209) of the back cleat clip fixing profile (203) maintains clearance fit with a dimension (109) of the back cleat clip fixing profile (1013).
As shown in FIG. 3, the back cleat clip fixing profile (1013) is provided with a punching surface (110). After assembling the back cleat clip (201) with the main frame (101) by press fitting, the punching surface (110) of the back cleat clip fixing profile (1013) of the main frame (101) corresponding to length of the back cleat clip (201) is plastically deformed by punching to permanently reduce the dimension (109) of the back cleat clip fixing profile (1013) locally for rigidly holding the back cleat clip (201) by plastically deforming the back cleat clip fixing profile (203). On deforming the punching surface (110) the back cleat clip fixing profile (1013) corresponding to length of the back cleat clip (201) in assembled condition with the back cleat clip (201), initially multiple sharp edges of the back cleat clip fixing profile (203) penetrates into the internal surface of the rectangular enclosed opening (106) due to plastic deformation of the rectangular enclosed opening (106) because of plastic deformation of the back cleat clip fixing profile (1013) followed by plastic deformation of the back cleat clip fixing profile (203). This results into rigid mechanical holding of the back cleat clip (201) by the back cleat clip fixing profile (1013) of the main frame (101).
FIG. 2 shows cross sectional view of an assembly of a back cleat clip (201) with a main frame (101) and mounting of a solar panel (301) on a mounting structure (401) as per present invention. FIG. 7 shows pictorial view of an assembly of a back cleat clip (201) with a main frame (101) as per present invention.
As shown in FIG. 2 and FIG. 7, the extruded profile with back cleat clip (100) for mounting of solar modules (301) as per present invention is consisting of a main frame (101) for supporting and holding solar module (301) and; back cleat clips (201) assembled with the main frame (101) for fixing of the main frame (101) holding the solar modules (301) on a mounting structure (401) using through slot (216) on a back cleat clip clamping surface (205) and fasteners.
As shown in FIG. 3 and FIG. 7, multiple back cleat clips (201) are assembled with the main frame (101) by press fitting them into the back cleat clip fixing profile (1013) as per required longitudinal clamping position depending on location of fixing holes provided on a mounting structure (401). The length of the main frame (101) is decided so that it can accommodate total length of the solar modules to be mounted.
In the present invention, the thickness dimensions (206, 207) of the L-shaped bend (204) and the back cleat clip clamping surface (205) respectively are varied as per the requirement depending upon the static and dynamic load acting upon the solar module and clamping forces for clamping of the extruded profile with back cleat clip (100) holding the solar modules (301) without changing design of the main frame (101). This results into reduction in overall weight of the extruded profile with back cleat clip (100) used for mounting of solar modules.
As clamping of the extruded profile with back cleat clip (100) holding solar modules (301) with the mounting structure (401) is done by fastening using the back cleat clips (201), clamping forces and hence related stresses are acting only on the back cleat clips (201) preventing failure of the main frame (101) due to clamping forces.
In conventional frame as per FIG. 1, made up of only an aluminium frame, 5.45 gram of aluminium per Watt capacity of the photovoltaic (PV) module is used. Conventional frames as per FIG. 1, has lower mechanical load bearing capacity and major focus is on cost saving by weight reduction. Conventional frame as per FIG. 1 consist of predefined fixed mounting holes and are suitable for only one kind of mounting system.
The extruded profile with back cleat clip (100) as per present invention is with better mechanical load bearing capacity without compromising aesthetic feature and weight increase. The proposed extruded profile with back cleat clip (100) is suitable for any kind of mounting structure i.e. it’s a universal frame for all type of solar module mounting applications. There is groove in the frame and is completely flexible with respect to any mounting hole location requirement without any restriction on mounting hole size and dimension.
In proposed design, maximum stress generated in the main frame material is reduced drastically. The modular frame prevents loosening of the fasteners and resulting vibrations due to dynamic in service loads acting on it because of use of the back cleat clips. The modular frame is having improved life span with more uniform stress distribution in the material of the main frame and especially suitable for upcoming bigger photovoltaic (PV) modules (e.g. 700 Wp). , Claims:We Claim:
1. An extruded profile with back cleat clip (100) for mounting of solar modules comprising of:
a main frame (101) for supporting and holding solar module (301) and;
back cleat clips (201) assembled with the main frame (101);
characterized in that
the main frame (101) is having a solar module gripping profile (1011), a main frame locking profile (1012) positioned adjacent to the solar module gripping profile (1011) and a back cleat clip fixing profile (1013) positioned adjacent to the main frame locking profile (1012) wherein
the solar module gripping profile (1011) is consisting of a support surface (102) for resting the solar module (301) and an upper projected profile (103) extending from the support surface (102) for gripping the solar module (301) against the support surface (102),
a gap dimension (112) between the support surface (102) and the upper projected profile (103) and a thickness dimension (113) of the upper projected profile (103) is maintained such that the upper projected profile (103) elastically deforms and firmly grips the solar module (301) resting on the support surface (102),
a sealant is applied at interface of the upper projected profile (103) and solar module (301) and, the support surface (102) and the solar module (301),
the main frame locking profile (1012) forms a rectangular enclosed opening (104) and is provided with projected longitudinal ribs (105) on its internal surface (114) wherein the main frame locking profile (1012) is used for assembling short and long main frame (101) with each other by using a key partially inserted into the short and long main frame (101) to be assembled wherein the main frame (101) assembled with width and length of the solar module (301) is named as short and long main frame (101) respectively,
outer dimensions of the key form interference fit with the dimensions of the rectangular enclosed opening (104),
the back cleat clip fixing profile (1013) forms a rectangular enclosed opening (106) and is provided with a pair of longitudinal wedge shaped rib (107) positioned opposite to each other on its internal surface (118) wherein the back cleat clip fixing profile (1012) is used for assembling the back cleat clips (201) at required longitudinal position on the main frame (101),
for assembling the back cleat clip (201) with the main frame (101), it is press fitted into the back cleat clip fixing profile (1012) of the main frame (101) by inserting it through back cleat clip insert openings (111) cut on a vertical rib (115) of the back cleat clip fixing profile (1012),
the pair of longitudinal wedge shaped rib (107) is provided with its taper surface (116) facing towards the vertical rib (115) on which the back cleat clip insert openings (111) are cut and its vertical surface (117) facing towards a vertical rib (118),
the back cleat clip (201) is provided with a back cleat clip positioning profile (202) at its one end (210), a back cleat clip fixing profile (203) connected to the cleat positioning profile (202) using a neck (211), an L-shaped bend (204) provided adjacent to the back cleat clip fixing profile (203), a back cleat clip clamping surface (205) extending from the L-shaped bend (204) and, a through slot (216) on a back cleat clip clamping surface (205),
a thickness dimension (206) of the L-shaped bend (204) and a thickness dimension (207) of the back cleat clip clamping surface (205) of the back cleat clip (201) is configured as per requirement without changing design of the main frame (101),
the back cleat clip positioning profile (202) is of a wedge shape cross-section having minimum dimension (212) at the end (210) and maximum dimension (213) at an another end (214),
a gap dimension (108) formed by the pair of longitudinal wedge shaped rib (107) is lesser than the maximum dimension (213) provided at the end (214) of the back cleat clip positioning profile (202),
the gap dimension (108), the dimension (213) and a wall thickness (119) of the back cleat clip fixing profile (1013) is configured such that on press fitting the back cleat clip (201), the back cleat clip fixing profile (1013) deforms elastically resulting into increase in the gap dimension (108) allowing the back cleat clip positioning profile (202) to completely cross the longitudinal wedge shaped rib (107) and locked in the back cleat clip fixing profile (1013),
a dimension (209) of the back cleat clip fixing profile (203) is provided to maintain clearance fit with a dimension (109) of the back cleat clip fixing profile (1013) in assembled condition and,
a punching surface (110) of the back cleat clip fixing profile (1013) corresponding to length of the back cleat clip (201) is plastically deformed by punching after press fitting the back cleat clip (201) into the back cleat clip fixing profile (1013) to reduce the dimension (109) for rigidly holding the back cleat clip (201) by plastically deforming the back cleat clip fixing profile (203).
2. The extruded profile with back cleat clip for mounting of solar modules as claimed in claim 1, wherein the main frame (101) is made up of a longitudinal extruded profile of aluminium material.
3. The extruded profile with back cleat clip for mounting of solar modules as claimed in claim 1, wherein the cleat clip (201) is made up of an aluminium material.
4. The extruded profile with back cleat clip for mounting of solar modules as claimed in claim 1, wherein multiple back cleat clips (201) are assembled with the main frame (101) by press fitting them into the back cleat clip fixing profile (1013) as per required longitudinal clamping position depending on location of fixing holes provided on a mounting structure (401).
5. The extruded profile with back cleat clip for mounting of solar modules as claimed in claim 1, wherein a length of the main frame (101) is configured to accommodate a length of the solar module.