Snap-on rail assembly

Patent metadata

Field	Value
Publication number	US-10177704-B2
Application number	US-201715497748-A
Country	US
Kind code	B2
Filing date	Apr 26, 2017
Priority date	Apr 26, 2017
Publication date	Jan 8, 2019
Grant date	Jan 8, 2019

Abstract

A mounting assembly to mount frames on a mounting surface, the mounting assembly having rails that supports the frames, each rail having an internal side adjacent with an internal recess, and an external side opposite to the internal side with lip; and roof mounting assemblies to affix the rails onto the mounting surface. Each mounting assembly having a mounting block that is fixable to the mounting surface, a mounting plate that is fixable to the mounting block, and a pair rail snap brackets formed at extremities of the mounting plate that receives and locks the rails in place, each rail snap bracket of the pair of rail snap brackets having a pair of notches that lodges in the internal recess of the rail to lock the rail in place and a hook that receives the lip.

First claim

What is claimed is:

1. A mounting assembly to mount solar modules on a mounting surface, the mounting assembly comprising:
a plurality of rails that support the solar modules, each rail of the plurality of rails including:
an internal side with an internal recess, and
an external side opposite to the internal side with a lip that protrudes outwardly; and

a plurality of roof mounting assemblies that secure the plurality of rails onto the mounting surface, each roof mounting assembly of the plurality of roof mounting assemblies including:
a mounting block that is fixable to the mounting surface,
a mounting plate that is fixable to the mounting block, and
a pair of rail snap brackets respectively formed at a first end and a second end of the mounting plate that receives and locks the plurality of rails in place, each rail snap bracket of the pair of rail snap brackets including:
a first support wall that protrudes from the mounting plate,
a pair of notches that protrude from the first support wall and are configured to engage the internal recess of the rail to lock the rail in place, wherein each notch of the pair of notches includes
a slanted portion with respect to the first support wall that contacts the rail and flexes when the rail is received in the rail snap bracket, and
a nonplanar portion adjacent to the slanted portion that is receivable in the internal recess when the rail is locked in place in the rail snap bracket,

a second support wall that protrudes from the first support wall between the pair of notches, and
a hook that is placed along an outward end of the second support wall and that is configured to engage the lip of the rail when the rail is being rotated toward the second support wall and the pair of notches flex inwardly to position the nonplanar portion of each pair of notches into the internal recess and lock the internal side of the rail against the first support wall of the rail snap bracket and a bottom side of the rail against the second support wall of the rail snap bracket.

2. The mounting assembly of claim 1 , wherein the notch further includes a planar portion that seats on a stop of the internal recess.

3. The mounting assembly of claim 1 , wherein the rail snap bracket further includes a tongue with a tongue hole and a tongue fastener inserted through the tongue hole and threaded in the internal recess to further lock the rail in the rail snap bracket.

4. The mounting assembly of claim 1 , wherein the mounting block includes a counter bore hole to receive a mounting block fastener that affixes the mounting block on the mounting surface.

5. The mounting assembly of claim 1 , further includes a flashing positioned between the mounting surface and the mounting block that prevents water infiltration to the mounting surface.

6. The mounting assembly of claim 1 , wherein the solar modules comprise a frame.

7. The mounting assembly of claim 1 , wherein the mounting surface is a roof.

8. A mounting assembly to mount frames on a mounting surface, the mounting assembly comprising:
a plurality of rails that support the frames, each rail of the plurality of rails including:
a top side with a top recess,
an internal side adjacent to the top side with an internal recess, and
an external side opposite to the internal side with a lip that protrudes outwardly;

a plurality of roof mounting assemblies to affix the plurality of rails onto the mounting surface, each roof mounting assembly of the plurality of roof mounting assemblies including:
a mounting block that is fixable to the mounting surface,
a mounting plate that is fixable to the mounting block, and
a pair rail snap brackets respectively formed at a first end and a second end of the mounting plate that receives and locks the plurality of rails in place, each rail snap bracket including:
a first support wall that protrudes from the mounting plate,
a pair of notches that protrude from the first support wall and are configured to engage the internal recess of the rail to lock the rail, wherein each notch of the pair of notches includes
a slanted portion with respect to the first support wall that contacts the rail and flexes when the rail is received in the rail snap bracket, and
a nonplanar portion adjacent to the slanted portion that is receivable in the internal recess when the rail is locked in place in the rail snap bracket,

a second support wall that protrudes from the first support wall between the pair of notches,
a hook that is placed along an outward end of the second support wall and that is configured to engage the lip of the rail when the rail is being rotated toward the second support wall and the pair of notches flex inwardly to position the nonplanar portion of each pair of notches into the internal recess and lock the internal side of the rail against the first support wall of the rail snap bracket and a bottom side of the rail against the second support wall of the rail snap bracket; and

a plurality of frame connectors to affix the frames onto the plurality of rails, each frame connector of the plurality of frame connectors including:
a guide rail in contact with the top side of the rail,
at least one pair of notches that protrudes from the guide rail and locks the solar panels, and
a frame connector fastener with a head that anchors the top recess of the top side and a body that threads into the guide rail.

9. The mounting assembly of claim 8 , wherein the guide rail includes:
a guide rail base,
a threaded hole placed on the guide rail base that receives the body of the frame connector fastener,
an internal guide rail wall that protrudes from the guide rail base and faces the internal side of the rail, and
an external guide rail wall that protrudes from the guide rail base and faces the external side of the rail.

10. The mounting assembly of claim 9 , wherein each notch of the at least one pair of notches includes a first pair of supporting walls that protrudes from the guide rail base and a pair of slanted portions with respect to the first support wall that is cut out from the first pair of supporting walls.

11. The mounting assembly of claim 10 , wherein each frame of the plurality of frames includes a ridge that is locked against the guide rail base by the pair of slanted portions of the at least one pair of notches.

12. The mounting assembly of claim 11 , wherein the frame connector includes a protrusion placed between the at least one pair of notches that is insertable in a ridge hole of the ridge.

13. The mounting assembly of claim 12 , wherein the plurality of frames supports a plurality of solar modules.

14. The mounting assembly of claim 13 , wherein the mounting surface is a roof.

15. A mounting assembly to mount frames on a mounting surface, the mounting assembly comprising:
a plurality of rails that support the frames, each rail of the plurality of rails including:
an open end,
a top side with a top recess,
an internal side adjacent to the top side with internal recess, and
an external side opposite to the internal side with a lip that protrudes outwardly;

a plurality of rail connectors to connect the plurality of rails from end to end, each rail connector of the plurality of rail connectors including:
an inner rail that receives a first open end of a first rail of the plurality of rails and a second open end of a second rail of the plurality of rails;

a plurality of roof mounting assemblies to affix the plurality of rails onto the mounting surface, each roof mounting assembly of the plurality of roof mounting assemblies including:
a mounting block tha

Assignees

• Sunpower Corp

Inventors

• Kapla John
• Feldmann Kyle
• Cusick Bryan

Classifications

• F16B5/126 Primary

  at least one of the sheets, plates, bars or strips having integrally formed or integrally connected snap-in-features · CPC title

• F16B5/123

  Auxiliary fasteners specially designed for this purpose · CPC title

• H02S20/23 Primary

  specially adapted for roof structures · CPC title

• F24S25/61

  for fixing to the ground or to building structures · CPC title

• F24S2025/021

  Sealing means between support elements and mounting surface · CPC title