INSERTION RAIL FOR A SOLAR MODULE MOUNTING SYSTEM

Abstract

An insertion rail for a solar panel mounting system is provided. The insertion rail has a mounting wall configured for connection to the solar panel mounting system, wherein the mounting wall is posited at a lower end of a first side of the insertion rail, a vertical leg coupled to the mounting wall at at least one location, wherein the vertical leg is positioned at a second side of the insertion rail, and at least one mating section located at an upper end of the insertion rail. The mating section has an upper tab, a lower tab and the upper tab and lower tab are configured to receive and secure a solar panel integrally therewith using an interference fit.

Claims

1. An insertion rail for a solar panel mounting system, the insertion rail comprising: a mounting wall configured for connection to the solar panel mounting system, wherein the mounting wall is posited at a lower end of a first side of the insertion rail; a vertical leg coupled to the mounting wall at at least one location, wherein the vertical leg is positioned at a second side of the insertion rail; at least one mating section located at an upper end of the insertion rail, wherein the mating section comprises: an upper tab; and a lower tab; wherein the upper tab and lower tab are configured to receive and secure a solar panel integrally therewith using an interference fit.

2. The insertion rail of claim 1, wherein the at least one mating section comprises a right mating section and a left mating section, wherein the right mating sections comprises a pair of right upper and lower tabs, and the left mating sections comprise a pair left upper and lower tabs, wherein the pair of right upper and lower tabs and the pair of left upper and lower tabs are configured to receive and secure consecutive solar panels of an array of solar panels.

3. The insertion rail of claim 2, further comprising a center spine integrated vertically between the right mating section and left mating section, wherein the right mating section and the left mating section extend outwardly perpendicular from the center spine.

4. The insertion rail of claim 1, wherein the mounting sections are configured to be secured to a horizontal supporting member of a frame the solar panel mounting system using one or more fasteners.

5. The insertion rail of claim 3, further comprising: an upper channel located at the upper end of the insertion rail, wherein the upper channel is formed by a top U-shaped member that connects the right tab, left tab, and the center spine at the upper end; a lower channel located at the lower end of the insertion rail, wherein the upper channel is formed by a bottom U-shaped member that connects the right tab, left tab, and the center spine the lower end; wherein the upper channel and lower channel provides reduced thermal convection between the consecutive solar panels.

6. The insertion rail of claim 1, wherein the vertical leg comprises an inward angle portion positioned on a lower end of the vertical leg.

7. The insertion rail of claim 1, further comprising a cleat, wherein the cleat connects the mounting wall and the vertical leg at a bottom portion of the insertion rail, and wherein the cleat is configured to connect or mate with the frame of the solar panel mounting system.

8. The insertion rail of claim 1, further comprising an upwardly bent hook extending from the cleat.

9. The insertion rail of claim 1, further comprising a center rib, wherein the center rib connects the mounting wall and the vertical leg at a middle portion of the insertion rail, and wherein the center rib provides additional structural support.

10. The insertion rail of claim 1, wherein the upper tab and lower tab comprise respective mating surfaces that form a right guide rail and a left guide rail, respectively.

11. The insertion rail of claim 1, wherein the tabs are formed of a flexible material and are configured to receive solar panels of varying thickness.

12. The insertion rail of claim 3, further comprising: at least one inner tab disposed perpendicularly with relation to the vertical spine; a plurality of internal channels formed by the at least one inner tab, wherein the internal channels provided to reduced thermal convection between the solar panels.

13. A solar panel mounting system comprising: a frame configured to support at least one solar panel; a plurality of mounting brackets connected to the frame; and plurality of support brackets connected to the frame; an insertion rail comprising: a mounting wall configured for connection to the solar panel mounting system, wherein the mounting wall is posited at a lower end of a first side of the insertion rail; a vertical leg coupled to the mounting wall at at least one location, wherein the vertical leg is positioned at a second side of the insertion rail; at least one mating section located at an upper end of the insertion rail, wherein the mating section comprises: an upper tab; and a lower tab; wherein the upper tab and lower tab are configured to receive and secure a solar panel integrally therewith using an interference fit.

14. The system of claim 13, wherein the at least one mating section comprises a right mating section and a left mating section, wherein the right mating sections comprises a pair of right upper and lower tabs, and the left mating sections comprise a pair left upper and lower tabs, wherein the pair of right upper and lower tabs and the pair of left upper and lower tabs are configured to receive and secure consecutive solar panels of an array of solar panels.

15. The system of claim 14, further comprising a center spine integrated vertically between the right mating section and left mating section, wherein the right mating section and the left mating section extend outwardly perpendicular from the center spine.

16. The system of claim 13, wherein the mounting section of the insertion rail are configured to be secured to the horizontal supporting member of the frame of the solar panel mounting system using one or more fasteners.

17. The system of claim 15, further comprising: an upper channel located at the upper end of the insertion rail, wherein the upper channel is formed by a top U-shaped member that connects the right tab, left tab, and the center spine at the upper end; a lower channel located at the lower end of the insertion rail, wherein the upper channel is formed by a bottom U-shaped member that connects the right tab, left tab, and the center spine the lower end; wherein the upper channel and lower channel provides reduced thermal convection between the consecutive solar panels.

18. The system of claim 13, wherein the insertion rail comprising a cleat, wherein the cleat connects the mounting wall and the vertical leg at a bottom portion of the insertion rail, and wherein the cleat is configured to connect or mate with the frame of the solar panel mounting system.

19. The system of claim 13, wherein the insertion rail further comprises an upwardly bent hook extending from the cleat.

20. The system of claim 15, wherein the insertion rail comprises at least one inner tab disposed perpendicularly with relation to the vertical spine; a plurality of internal channels formed by the at least one inner tab, wherein the internal channels provided to reduced thermal convection between the solar panels.

Description

BRIEF DESCRIPTION OF DRAWINGS

[0017] The foregoing summary, as well as the following detailed description of the invention, is better understood when read in conjunction with the appended drawings. For the purpose of illustrating the invention, exemplary constructions of the invention are shown in the drawings. However, the invention is not limited to the specific methods and structures disclosed herein. The description of a method step or a structure referenced by a numeral in a drawing is applicable to the description of that method step or structure shown by that same numeral in any subsequent drawing herein.

[0018] FIG. 1 illustrates a side view of solar mounting system having an insertion rail for a solar panel mounting system according to an embodiment of the present invention.

[0019] FIG. 2 illustrates an enlarged view of the insertion rail according to one embodiment of the present invention.

[0020] FIG. 3 illustrates an enlarged perspective view of the insertion rail according to one embodiment of the present invention.

[0021] FIG. 4 illustrates a perspective view of the insertion rail, according to one embodiment of the present invention.

[0022] FIG. 5 illustrates another side view of an insertion rail for a solar panel mounting system according to another embodiment of the present invention.

[0023] FIG. 6 illustrates another enlarged view of the insertion rail according to another embodiment of the present invention.

[0024] FIG. 7 illustrates a perspective view of the insertion rail according to another embodiment of the present invention.

[0025] FIG. 8 illustrates another side view of the insertion rail according to another embodiment of the present invention.

[0026] Other features, advantages, and aspects of the present invention will become more apparent and be more readily understood from the following detailed description, which should be read in conjunction with the accompanying drawings.

DETAILED DESCRIPTION OF THE INVENTION

[0027] The present invention is best understood by reference to the detailed figures and description set forth herein.

[0028] Embodiments of the invention are discussed below with reference to the examples. However, those skilled in the art will readily appreciate that the detailed description given herein with respect to these examples is for explanatory purposes as the invention extends beyond these limited embodiments. For example, it should be appreciated that those skilled in the art will, in light of the teachings of the present invention, recognize a multiplicity of alternate and suitable approaches, depending upon the needs of the particular application, to implement the functionality of any given detail described herein, beyond the particular implementation choices in the following embodiments described and shown. That is, there are numerous modifications and variations of the invention that are too numerous to be listed but that all fit within the scope of the invention. Also, singular words should be read as plural and vice versa and masculine as feminine and vice versa, where appropriate, and alternative embodiments do not necessarily imply that the two are mutually exclusive.

[0029] It is to be further understood that the present invention is not limited to the particular methodology, compounds, materials, manufacturing techniques, uses, and applications, described herein, as these may vary. It is also to be understood that the terminology used herein is used for the purpose of describing particular embodiments only, and is not intended to limit the scope of the present invention. It must be noted that as used herein and in the appended claims, the singular forms “a,” “an,” and “the” include the plural reference unless the context clearly dictates otherwise. Thus, for example, a reference to “an element” is a reference to one or more elements and includes equivalents thereof known to those skilled in the art. Similarly, for another example, a reference to “a step” or “a means” is a reference to one or more steps or means and may include sub-steps and subservient means. All conjunctions used are to be understood in the most inclusive sense possible. Thus, the word “or” should be understood as having the definition of a logical “or” rather than that of a logical “exclusive or” unless the context clearly necessitates otherwise. Structures described herein are to be understood also to refer to functional equivalents of such structures. Language that may be construed to express approximation should be so understood unless the context clearly dictates otherwise.

[0030] Unless defined otherwise, all technical and scientific terms used herein have the same meanings as commonly understood by one of ordinary skill in the art to which this invention belongs. Preferred methods, techniques, devices, and materials are described, although any methods, techniques, devices, or materials similar or equivalent to those described herein may be used in the practice or testing of the present invention.

[0031] It is expected that the present invention may be embodied in other specific forms without departing from its spirit or essential characteristics. The described embodiments are to be considered in all respects only as illustrative and not restrictive. The scope of the invention is, therefore, indicated by the appended claims rather than by the foregoing description. All changes that come within the meaning and range of equivalency of the claims are to be embraced within their scope.

[0032] Referring to FIG. 1, a solar mounting system having an insertion rail 100 for a solar panel mounting system is disclosed. In one embodiment, the insertion rail 100 is configured to slidably receive and secure solar panels 102 on both sides of the rail (e.g., east/west or side to side) via a friction fit without the need for any additional mounting hardware. In one embodiment, the insertion rail 100 is further configured to securely connect to the solar panel mounting system using one or more fasteners, for example, threaded bolts (shown in greater detail with relation to FIG. 2). In one embodiment, the solar panel mounting system comprises a frame 104, and the frame 104 comprises a plurality of mounting brackets 112 and support brackets 114. In one embodiment, the insertion rail 100 eliminates approximately twenty-five percent (25%) of the east-west beams in the solar panel mounting system. This reduces the mounting bolt count to two fasteners per module, substantially reducing installation costs and increasing the speed.

[0033] The racking system in which the insertion rail 100 is integral comprises a plurality of mounting and support members, including but not limited to vertical mounting members 108, horizontal support members 111 and diagonal support members 106 and 110. In one embodiment, one end of the support members 106 and 110 are pivotally connected to the horizontal supporting members 111, while and other ends are secured to the vertical mounting member 108. The vertical mounting members 108 and the support members 106 and 110 are pivotally connected to the horizontal supporting members 111 and configured to adjust and align the solar panels 102 at the correct or optimized angle. In one embodiment, one end of the vertical mounting members 108 are pivotally connected to the horizontal supporting member 111 via a bracket 113. The horizontal support members 111 support the solar panels 102 together with the insertion rail 100 and support brackets 114. The insertion rail 100 and supporting brackets 114 are securely connected to the horizontal supporting members 111 on both sides via mounting brackets 112.

[0034] Referring now to FIG. 2, an enlarged view of the insertion rail 100 according to one embodiment of the present invention is shown. The insertion rail 100 is configured to receive and secure the solar panels 102 and is further configured to slidably receive and frictionally secure the solar panels 102 on both sides using a frictional fit or engagement thereby eliminating approximately 600,000 bolts and nuts per 100 MW. In one embodiment, the insertion rail 100 is secured to the horizontal supporting member 111 of the frame 104 on both sides via the mounting brackets 112 using one or more fasteners 202. In one embodiment, the insertion rail 100 further comprises one or more upper and lower channels 204 and 206 respectively at a top portion and a bottom portion, thereby providing aesthetic and thermal benefits due to the spacing provided by the channels 204 and 206. The channels are on an upper channel located at the upper end of the insertion rail 100 and are formed by a top and bottom U-shaped member (240 and 242) that connects the right tabs 208 and 210, left tabs 212 and 214, and the center spine 216.

[0035] Referring still to FIG. 2, the rail 100 further comprises a right mating section comprising right upper tab 208 and right lower tab 210, and a left mating section comprising left upper tab 212 and left lower tab 214. These mating sections provide a friction fit (also known as interference fit or press fit) and fasten the consecutive solar panels 102 or modules to form a joint (or “guide rail”) which is held together by friction after the parts are pushed together. The rail 100 further comprises a center spine 216 integrated vertically between the top joint 218 and bottom joint 220. The spine 218 is configured to provide structural integrity to the rail 100.

[0036] The insertion rail 100 further comprises a mounting wall 222 on its right side, and a vertical leg 224 on its left side (as used herein “left” and “right” may mean “one side” and “the other side” as the elements are interchangeable from one side to the other). The mounting wall 222 may comprise a plurality of mounting holes to connect the rail 100 to the mounting bracket 112. In other embodiments, the mounting wall 222 may not have mounting holes and may be drilled through on site so that the fasteners 202 connect the rail 100 to the mounting system.

[0037] The vertical leg 224, which is positioned on the other side of rail 100 relative to the mounting wall 222, comprises an inward angle 230 positioned on a downward end of the vertical leg 224 before bending into a cleat 228, and further bending upwardly into a hook 232. A center rib 226 connects the mounting wall to the vertical leg 224 to provide additional support. In embodiments, the cleat 230 mates or rests on the frame 104.

[0038] Referring now to FIG. 3, an enlarged perspective view of the insertion rail or FIG. 2 is shown. As with FIGS. 1 and 2, the insertion rail 100 is configured to receive and secure the solar panels 102 and is further configured to slidably receive and frictionally secure the solar panels 102 on both sides using a friction fit. In one embodiment, the insertion rail 100 is secured to the horizontal supporting member 111 of the frame 104 on both sides via the mounting brackets 112 using one or more fasteners 202. In this view, the right side 302 of the insertion rail 100 is shown. Further, in this view, the right upper tab 208 and right lower tab 210 can be seen forming the mating joint with the solar panels 102. The center spine 216 that integrated vertically between the top joint 218 and bottom joint 220 can also be seen. The spine 218 is configured to provide structural integrity to the rail 100. Left side 304 is shown by the reference arrow but is not visible.

[0039] Referring now to FIG. 4, an enlarged top perspective view of the insertion rail of FIG. 2 and FIG. 3 is shown, but in this embodiment, without the solar panels 102 connected thereto via the interference fit. As with FIG. 3, the insertion rail 100 is configured to receive and secure the solar panels 102 and is further configured to slidably receive and frictionally secure the solar panels 102 on both sides of the joint using a friction fit. In this view, the right side 302 of the insertion rail 100 is shown, and the depth of the rail is shown. The right upper tab 208 and right lower tab 210 can be seen forming the mating joint, and further comprises a right lower mating surface 402, lower left mating surface 404, upper right mating surface 406, and upper left mating surface 408. These mating surfaces form guide rails 410 and 412. In this way, as can be seen, the rail is configured as a purlin.

[0040] In one embodiment, the joint, which formed by the tabs 208, 210, 212 and 214 is flexible to receive the solar panels 102 of various thicknesses. Electrical bonding is maintained from the solar panels 102 to the solar panel mounting system at the top and bottom of attachment points via north and south purlins 114 of the vertical mounting members 108, the horizontal supporting members 111, and the support members 106 and 110. In one embodiment, the solar panels 102 may snap into pair of joints (or guide rails) 410 and 412 on both sides of the insertion rail 100 by a person or a technician. In one embodiment, the clamp (tabs plus guide rails) or rail 100 as a whole may be formed from, but not limited to, an aluminum extrusion and 6061 or 6063 mill-finish aluminum alloy.

[0041] In one embodiment, the first vertical element 118 further comprises one or more holes configured to threadedly receive fasteners 202 (shown in FIG. 2), for example, threaded bolts, for securely affixing the insertion rail 100 to the mounting bracket 112 (shown in FIG. 1) of the frame 104 (shown in FIG. 1). In one embodiment, a length of each insertion rail 100 is approximately equal to a length of the solar panel 102. In one embodiment, the insertion rail 100 is further configured to slidably receive and frictionally secure the solar panels 102 of thicknesses ranges from about, but not limited to, 35 to 40 mm. In one embodiment, the insertion rail 100 is made of, but not limited to, aluminum.

[0042] Referring now to FIG. 5, the insertion rail 200 for a solar panel mounting system in another embodiment is disclosed. In another embodiment, the insertion rail 200 is configured to slidably receive and frictionally secure the solar panels 102 on both sides via a frictional fit or frictional engagement. In one embodiment, the insertion rail 200 is further configured to securely affix to the solar panel mounting system using one or more fasteners, for example, threaded bolts. In one embodiment, the solar panel mounting system having a frame 111. Like in FIG. 1, the frame 104 comprises a plurality of mounting brackets comprising vertical mounting members 108, horizontal supporting members 111, and support members 106 and 110. In one embodiment, one end of the support members 106 and 110 are pivotally connected to the horizontal supporting members 111 and other ends are secured to the vertical mounting member 108. In one embodiment, one ends of the vertical mounting members 108 are pivotally connected to the horizontal supporting member 111 via a bracket 113. In one embodiment, the horizontal supporting members 111 supports the solar panels 102 via the insertion rail 100 and supporting brackets 114 (or north/south purlins). In one embodiment, the insertion rail 100 and supporting brackets 114 are securely affixed to the horizontal supporting members 111 on both sides via mounting brackets 112. However, in this embodiment, the bracket 113 is attached to the mounting member 108 via a series of lower fasteners 502.

[0043] Referring now to FIG. 6, another embodiment of an insertion rail is shown generally at 200. The insertion rail 200 is configured to receive and secure the solar panels 102. In one embodiment, the insertion rail 200 is configured to slidably receive and frictionally secure the solar panels 102 on both sides using a frictional fit or engagement.

[0044] In this embodiment, rather than there being upper and lower channels (204 and 206 of FIG. 2, respectively) at a top portion and a bottom portion of the rail 100, there are multiple internal channels 602, 604, 606, 608, 610 and 612. These channels are formed by top tabs 212 and 208, bottom tabs 210 and 214, and a plurality of inner tabs 614 and 618. The tabs provide advantageous thermal properties due to separation and the channels, and also provide additional mating surfaces with the panel 102.

[0045] Furthermore, the vertical leg 224, which is positioned on the other side of rail 100 relative to the mounting wall 222, has an approximately flat configuration and no inward angle positioned on a downward end of the vertical leg 224 before being integral with the cleat 228 as with the embodiment shown in FIG. 2. In one embodiment, the insertion rail 200 is further configured to provide one or more channels (210, 212, and 214) on both sides at a guide rail portion, thereby providing aesthetic and thermal benefits.

[0046] Referring now to FIG. 7, a right perspective view of the insertion rail 200 of the present invention according to another embodiment is disclosed wherein the right side 702 of the rail is shown. In this view, the inner tabs 614 and 618 and protrusions (described in FIG. 8) can be clearly seen.

[0047] Referring now to FIG. 8, a side view of the insertion rail 200 is disclosed. In one embodiment, the internal tabs 614 and 618 comprise protrusions 802, 804, 806, and 808. The protrusions are configured ensure channels are formed between the spine and the solar panels when they are mounted to the rail.

[0048] In one embodiment, the insertion rail 200 is further configured to slidably receive and frictionally secure the solar panels 102 of thicknesses ranges from about, but not limited to, 35 to 40 mm. In one embodiment, the solar panels 102 could simply snap into pair of guide rails on both sides of the insertion rail 100 by a person or a technician.

[0049] The advantages of the present invention include, the insertion rails (100 and 200) are configured to enable the person or technician to simply and quickly mount the solar panels 102 without using more fasteners, for example, bolts and nuts. The insertion rails (100 and 200) are adaptable for mounting the solar panels 102 of various thicknesses ranges from about, but not limited to, 35 mm to 40 mm. The insertion rails (100 and 200) are configured to slidably receive and frictionally secure the solar panels 102 on both sides via a frictional fit or frictional engagement, thereby eliminating approximately 600,000 bolts and nuts per 100 MW and saving work of 4000 man-hours per 100 MW. The insertion rails (100 and 200) are a sturdy, compact, durable, simple, safe, versatile, reliable, and yet inexpensive and easy to manufacture and install.

[0050] Preferred embodiments of this invention are described herein, including the best mode known to the inventors for carrying out the invention. It should be understood that the illustrated embodiments are exemplary only and should not be taken as limiting the scope of the invention.

[0051] Although specific features of various embodiments of the invention may be shown in some drawings and not in others, this is for convenience only. In accordance with the principles of the invention, the feature(s) of one drawing may be combined with any or all of the features in any of the other drawings. The words “including,” “comprising,” “having,” and “with” as used herein are to be interpreted broadly and comprehensively, and are not limited to any physical interconnection. Moreover, any embodiments disclosed herein are not to be interpreted as the only possible embodiments. Rather, modifications and other embodiments are intended to be included within the scope of the appended claims.