PHOTOVOLTAIC MODULE SUPPORT SYSTEM AND MOUNT ASSEMBLY
20250293636 ยท 2025-09-18
Inventors
- Deepthi Gangumalla (Hyderabad, IN)
- Sindhu Madhavi Gopalam (Hyderabad, IN)
- Nikhil Babu (Hyderabad, IN)
- Austin GRAHAM (Albuquerque, NM, US)
Cpc classification
F24S25/13
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F24S2025/803
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F24S25/634
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F24S2025/6006
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
International classification
F24S25/13
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
Abstract
A mounting assembly including a rail and a clip. The rail configured to support a photovoltaic module and including a first slot, a second slot, and a web extending between the first slot and the second slot. The web offset from a plane extending along an outer surface of the rail and forming a recess in the second side of the rail. The clip being configured to be secured to the rail and to a bracket so as to couple the rail to the bracket. The clip including a base having a flange extending in a first direction and an arm extending in a second direction opposite the first direction. The flange being inserted in the second slot when the clip couples the rail to the bracket. At least a portion of the arm abutting the recess of the rail when the clip secures the rail to the bracket.
Claims
1. A mounting assembly comprising: a rail to support a photovoltaic module, the rail including: a first slot formed in a first side of the rail, a second slot formed in a second side of the rail, and a web extending between the first slot and the second slot, the web being offset from a plane extending along an outer surface of the second side of the rail, so as to form a recess in the second side of the rail; and a clip including: a base having a flange extending from an end of the base in a first direction, the flange being inserted in the second slot of the rail when the clip is secured to the rail, and an arm extending from the end of the base in a second direction opposite the first direction, at least a portion of the arm abutting the recess of the rail when the clip is secured to the rail.
2. The mounting assembly of claim 1, further comprising a bracket that is an L-foot bracket that is attachable to the base of the clip, the bracket including: a base extending in a first direction, the base having a first aperture extending therethrough in a second direction that is substantially perpendicular to the first direction, and a leg connected to the base of the bracket, the leg extending in the second direction, and the leg having: a second aperture extending through the leg in the first direction, a perimeter shape of the first aperture being elongated along the leg in the second direction, and a third aperture extending through the leg in the first direction, the second aperture having a perimeter shape that is elongated and curved so as to form an arc.
3. The mounting assembly of claim 2, wherein the clip includes an aperture through a thickness of the base of the clip, whereby the clip is securable to the bracket via insertion of a fastener through the aperture in the base of the clip and into the first aperture in the base of the bracket.
4. The mounting assembly of claim 2, wherein: the rail is a first rail, the mounting assembly further includes a second rail having a slot therein, the bracket is securable to the second rail via insertion of at least one of: a first fastener through the second aperture of the bracket, and a second fastener through the third aperture of the bracket, and the first fastener and the second fastener are secured within the slot of the second rail.
5. The mounting assembly of claim 2, wherein the flange is a first flange, the end is a first end, and the base further includes a second flange extending from a second end of the base in the first direction, and wherein the second flange spaces the base of the clip from the bracket by a distance when the clip is secured to the bracket.
6. The mounting assembly of claim 1, wherein the rail includes a cavity extending along a length of the rail.
7. The mounting assembly of claim 6 wherein the rail is a first rail, and the mounting assembly further comprising: a second rail including a cavity, and a splice rail including: a first end shaped to fit within the cavity of the first rail, and a second end opposite the first end, the second end shaped to fit within the cavity of the second rail.
8. The mounting assembly of claim 1, wherein: the plane is a first plane, the outer surface is a first outer surface, and the first slot is disposed below a second plane extending along a second outer surface of the rail.
9. The mounting assembly of claim 1, further comprising a second rail configured to support the photovoltaic module, the second rail including: a first slot formed in a first side of the second rail, a second slot formed in a second side of the second rail, and a web extending between the first slot and the second slot, the web being offset from a plane extending along an outer surface of the rail, so as to form a recess in the second side of the second rail.
10. A mounting assembly comprising: a first rail extending in a first direction, the first rail including: a first slot formed in a first side of the first rail, and a second slot formed in a second side of the first rail; a clip including: a base extending in the first direction, the base having an aperture extending therethrough in a second direction that is substantially perpendicular to the first direction, a flange extending from an end of the base in the second direction transverse to the first direction, an arm extending from the end of the base in a third direction opposite the second direction, and a fastener extendable through the aperture of the base when the clip is secured to the first rail, a portion of the fastener being securable within the first slot of the first rail; and a second rail extending in a fourth direction transverse to the first direction, the second rail including: a first slot formed in a first side of the second rail, a second slot formed in a second side of the second rail, and a web extending between the first slot of the second rail and the second slot of the second rail, the web being offset from a plane extending along an outer surface of the second side of the second rail, so as to form a recess in the second side of the second rail, wherein the flange of the clip is disposed within the second slot of the second rail when the clip is secured to the second rail, and at least a portion of the arm of the clip abuts the web when the clip is secured to the second rail.
11. The mounting assembly of claim 10, wherein the first side of the second rail is shaped to engage with a photovoltaic module.
12. The mounting assembly of claim 10, wherein the second slot in the second side of the first rail is shaped to receive a bracket.
13. The mounting assembly of claim 12, wherein the bracket includes: a body extending in the second direction, the body having a first aperture extending therethrough in a fourth direction that is substantially perpendicular to the second direction, whereby the bracket is securable to a third rail via insertion of a first fastener through the first aperture with a portion of the first fastener being secured within the third rail, and a protrusion extending from an end of the body in the fourth direction, the protrusion having a second aperture extending therethrough in the fourth direction, whereby the bracket is securable to the first rail via insertion of a second fastener through the second aperture with a portion of the second fastener being secured within the second slot of the first rail, wherein the protrusion is disposed within the second slot in the second side of the first rail when the bracket is secured to the first rail.
14. The mounting assembly of claim 10, wherein: the second rail further including a cavity extending along a length of the second rail, and the mounting assembly further includes a splice rail including: a first end shaped to fit within the cavity of the second rail, and a second end shaped to fit within a cavity of a third rail.
15. The mounting assembly of claim 14, wherein the first end of the splice rail is at least partially insertable within the cavity of the second rail, and the second end of the splice rail is at least partially protruding out of the cavity of the second rail, when the first end of the splice rail is inserted within the cavity of the second rail.
16. A mounting assembly comprising: a rail extending in a first direction, the rail including: a first slot formed in a first side of the rail, a second slot formed in a second side of the rail, and a web extending between the first slot and the second slot, the web being offset from a plane extending along an outer surface of the rail, so as to form a recess in the second side of the rail; a clip assembly securable to the first slot of the rail via a first fastener extending therethrough; and a bracket securable to the second slot of the rail via a second fastener extending therethrough.
17. The mounting assembly of claim 16, wherein the clip assembly includes: a base extending in the first direction, the base having an aperture extending therethrough in a second direction that is substantially perpendicular to the first direction, a flange extending from an end of the base in the second direction transverse to the first direction, an arm extending from the end of the base in a third direction opposite the second direction, and a fastener extending through the aperture of the base when the clip assembly is secured to the rail, a portion of the fastener being secured within the first slot of the rail.
18. The mounting assembly of claim 17, further including a second rail including: a first slot formed in a first side of the second rail, a second slot formed in a second side of the second rail, and a web extending between the first slot of the second rail and the second slot of the second rail, the web of the second rail being offset from a plane extending along an outer surface of the second side of the second rail, so as to form a recess in the second side of the second rail, wherein the flange of the clip assembly is disposed within the second slot of the second rail when the clip assembly is secured to the second rail, and at least a portion of the arm of the clip assembly abuts the web when the clip assembly is secured to the second rail.
19. The mounting assembly of claim 16, wherein the rail is a first rail, and the bracket includes: a body extending in a second direction, the body having a first aperture extending therethrough in a third direction that is substantially perpendicular to the second direction, whereby the bracket is securable to a second rail extending in the second direction via insertion of a first fastener through the first aperture with a portion of the first aperture being securable within the second rail, and a protrusion extending from an end of the body in the third direction, the protrusion having a second aperture extending therethrough in the third direction, whereby the bracket is securable to the first rail via insertion of a second fastener through the second aperture with a portion of the second fastener being secured within the second slot in the second side of the first rail, and wherein the protrusion is disposed within the second slot in the second side of the first rail when the bracket is secured to the first rail.
20. The mounting assembly of claim 16 wherein: the rail is a first rail, the mounting assembly further including: a second rail extending in a second direction transverse to the first direction, the second rail having a slot extending along a side of the second rail, and a third rail extending in a third direction transverse to the second direction, the third rail having a slot extending along a side of the third rail, the clip assembly is secured to the first slot of the first rail and the slot of the second rail, and the bracket is secured to the second slot of the first rail and the slot of the third rail.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0003] The Detailed Description is set forth with reference to the accompanying figures. In the figures, the left-most digit(s) of a reference number identifies the figure in which the reference number first appears. The use of the same reference numbers in different figures indicates similar or identical items. Furthermore, the drawings may be considered as providing an approximate depiction of the relative sizes of the individual components within individual figures. However, the drawings are not to scale, and the relative sizes of the individual components, both within individual figures and between the different figures, may vary from what is depicted. In particular, some of the figures may depict components as a certain size or shape, while other figures may depict the same components on a larger scale or differently shaped for the sake of clarity.
[0004]
[0005]
[0006]
[0007]
[0008]
[0009]
[0010]
[0011]
[0012]
[0013]
[0014]
[0015]
DETAILED DESCRIPTION
[0016] This disclosure is directed to a support system for supporting one or more photovoltaic (PV) modules (or solar panels). The support system includes various components that are configurable in one or more configurations (or mounting assemblies) to comprise portions of the support system for the PV modules. Embodiments of the support system disclosed herein may be used on a roof or other structure and the support system provides components that are easily configurable between different assemblies that form different portions of the support system. As such, components of the support system may be implemented in multiple different configurations, thereby increasing the versatility of individual components of the support system and potentially reducing an amount of different types of components required to construct the support system.
[0017] Specifically,
[0018] The support system 100 may include one or more rails 104. In an embodiment, the rails 104 may be identical or substantially similar components (shown and described with respect to
[0019]
[0020] In an embodiment, the rail 104 may also include a second slot 210. The second slot 210 may be formed in a second side 212 of the rail 104. As such, the second slot 210 may be oriented such that an opening 214 of the second slot 210 is formed in the second side 212 of the rail 104. As shown in
[0021] In an embodiment, the rail 104 may include a web 218 extending between the first slot 202 and the second slot 210. The web 218 may extend in a substantially vertical direction. Furthermore, the web 218 may be offset from the plane of the second outer surface 216 of the rail 104, thereby forming a recess 220 in the second side 212 of the rail 104. In an embodiment, the recess 220 may be shaped to receive at least a portion of a bracket, clip, or other component of the support system 100 therein. Furthermore, in an embodiment, the rail 104 may include a cavity 222 extending along a length of the rail 104. The cavity 222 may be continuous along the length of the rail 104 and may be shaped to receive a splice rail (shown and described with respect to
[0022]
[0023]
[0024] The clip 402 further includes a second flange 412 extending from a second end 414 of the base 404 in a third direction that is substantially parallel with the first direction. The second flange 412 provides space between the base 404 of the clip 402 and a component to which the clip assembly 400 is secured by a fixed distance.
[0025] Furthermore, the base 404 of the clip 402 includes an aperture 416 through a thickness of the base 404 that is configured to receive at least a portion of a fastener 418 therein. In an embodiment, the fastener 418 may include a threaded rod 420 to which a nut 422 is configured to be secured to a first end of the fastener 418. For example, the nut 422 may include an aperture 424 therein that includes threading that is configured to correspond with threading of the fastener 418 such that when the fastener 418 is rotated, a relative position of the fastener 418 and/or the nut 422 is adjusted. In an embodiment, the nut 422 may be an elongated I-shaped nut that is shaped to be insertable into the first slot 202 or the second slot 210 of the rail 104. As such, the nut 422 may be secured via a longitudinal side thereof to a slot of the rail 104, i.e., one side or half of the I shape of the nut 422 forms a T shape, which is accommodated within a slot of the rail 104 when the clip assembly 400 is secured to the rail 104. The fastener 418 further includes a hex nut 426 that is configured to be secured to a second end of the fastener 418. In an alternative embodiment, the hex nut 426 may be a bolt head that is integral with the threaded rod 420. As shown in
[0026]
[0027]
[0028]
[0029]
[0030] The clip assembly 400 may be configured to be secured to the crossmember 608 and the longitudinal member 604, thereby coupling the crossmember 608 to the longitudinal member 604. For example, the clip 402 includes a base 404 having a first flange 406 extending from the base 404 in a first direction. The first flange 406 is configured to be inserted into the second slot 210 of the crossmember 608, as shown in
[0031] Furthermore, the nut 422 of the clip assembly 400 is inserted into a slot of the longitudinal member such that the nut 422 is secured therein. The fastener 418 may be adjusted to in order to secure the clip 402 to the longitudinal member 604 while also exerting a down force on the crossmember 608 via the flange 406 and the arm 410 of the clip 402. As such, the clip assembly 400 may be configured to couple the longitudinal member to the crossmember 608.
[0032]
[0033] Furthermore, as shown in
[0034]
[0035]
[0036] In an embodiment, a single fastener 1110 may be selectively inserted in one of the apertures (e.g., either the elongated aperture 1108 or the curved apertures 1104) depending on a load of the support system 100 and/or PV modules 102. For example, if the support system 100 and/or PV modules 102 exert a load on the L-foot bracket 1102 that is below a predetermined threshold, a single fastener may be used to attach the L-foot bracket 1102 to the leg 602 of the support system 100. However, if the support system 100 and/or PV modules 102 exert a load on the L-foot bracket 1102 that is above a predetermined threshold, multiple fasteners may be used to secure the L-foot bracket 1102 to the leg 602 of the support system 100.
[0037]
[0038] As shown in
Conclusion
[0039] Although several embodiments have been described in language specific to structural features and/or methodological acts, it is to be understood that the claims are not necessarily limited to the specific features or acts described. Rather, the specific features and acts are disclosed as illustrative forms of implementing the claimed subject matter.