Hybrid solar panel mounting assembly

Patent metadata

Field	Value
Publication number	US-12289078-B2
Application number	US-202318545773-A
Country	US
Kind code	B2
Filing date	Dec 19, 2023
Priority date	Aug 3, 2015
Publication date	Apr 29, 2025
Grant date	Apr 29, 2025

Abstract

An apparatus and method for mounting a solar panel array on a surface is disclosed. The solar panel array includes a plurality of solar panel modules and a hybrid solar panel module mounting assembly. The hybrid solar panel module mounting assembly includes a component of a rail-based mounting system and a component of a rail-less mounting system. At least one of the plurality of solar panel modules is mounted on the component of the rail-based mounting system and at least one of the plurality of solar panel modules is mounted on the component of the rail-less mounting system.

First claim

What is claimed is:

1. A mounting system comprising:
a rail including:
a first track, and
a second track oriented perpendicular to the first track;

a rail clamp including a first connection portion to be at least partially disposed within the first track, the first connection portion connecting the rail clamp to the rail, such that upon installation, the rail clamp is retained by the rail;
a mount including a second connection portion to be at least partially disposed within the second track, the second connection portion connecting the mount to the rail, such that upon installation, the mount couples the rail to a mounting surface;
a floating splice including:
an upper bracket having:
a first vertical body,
a first arm extending from the first vertical body, and
a second arm extending from the first vertical body, and

a lower bracket having:
one or more grooves to receive at least a portion of the first vertical body,
a second vertical body,
a third arm extending from the second vertical body, and
a fourth arm extending from the second vertical body; and

a fastener to couple the upper bracket and the lower bracket together such that a first solar module is secured between the first arm and the third arm, and a second solar module is secured between the second arm and the fourth arm.

2. The mounting system of claim 1 , wherein:
the third arm is unattached to the mounting surface; and
the fourth arm is unattached to the mounting surface.

3. The mounting system of claim 1 , wherein:
a first distance extends between a first lateral edge of the first arm and a second lateral edge of the second arm; and
a second distance extends between a third lateral edge of the third arm and a fourth lateral edge of the fourth arm, the second distance being greater than the first distance.

4. The mounting system of claim 1 , wherein:
the rail clamp includes a fifth flange and a sixth flange; and
one or more serrations are disposed on the fifth flange or the sixth flange.

5. The mounting system of claim 1 , wherein:
the rail clamp couples to a first side of the first solar module;
the floating splice couples to a second side of the first solar module; and
the floating splice couples to a third side of the second solar module.

6. The mounting system of claim 1 , wherein the first arm and the second arm extend transversely from the first vertical body.

7. A mounting system for solar modules comprising:
a rail;
a clamp variably disposed along the rail;
one or more mounts to couple the rail to a mounting surface;
a connector floating above the mounting surface and unattached to the mounting surface, the connector including:
a first bracket having:
a first arm, and
a second arm extending in an opposite direction as the first arm, and

a second bracket having:
a third arm, and
a fourth arm extending in an opposite direction as the third arm; and

a fastener to couple the first bracket and the second bracket together such that the connector connects at least a first solar module of the solar modules and a second solar module of the solar modules.

8. The mounting system of claim 7 , wherein the connector connects a third solar module of the solar modules and a fourth solar module of the solar modules.

9. The mounting system of claim 7 , wherein the connector is exclusively coupled to the solar modules.

10. The mounting system of claim 7 , wherein the rail includes:
a first end;
a second end opposite the first end;
a first track extending between the first end and the second end;
a second track extending between the first end and the second end;
a first portion of the clamp engages with the first track; and
a second portion of the one or more mounts engage with the second track.

11. The mounting system of claim 7 , wherein the connector planarly aligns a first top of the first solar module with a second top of the second solar module.

12. The mounting system of claim 7 , wherein:
the first bracket includes a vertical body having a protrusion;
the second bracket includes a corrugation; and
the protrusion engages with the corrugation.

13. The mounting system of claim 7 , wherein:
the first solar module includes:
a first side,
a second side opposite the first side,
a third side,
a fourth side opposite the third side,
a first top, and
a first bottom;

the second solar module includes:
a fifth side,
a second top, and
a second bottom;

the clamp engages the first top;
the rail extends in a direction between the first side and the second side;
the first bottom rests on the rail, at a location between the third side and the fourth side; and
the connector connects to the third side and to the fifth side.

14. The mounting system of claim 13 , wherein:
the first arm is disposed adjacent to the first top;
the second arm is disposed adjacent to the second top;
the third arm is disposed adjacent to the first bottom; and
the fourth arm is disposed is adjacent to the second bottom.

15. A mounting system for solar modules, comprising:
one or more mounts coupled to a mounting surface;
a rail coupled to the one or more mounts;
a first clamp disposed along the rail;
a second clamp coupled to a first solar module of the solar modules and a second solar module of the solar modules, the second clamp being unattached to the rail, the second clamp including:
a first bracket having:
a vertical body,
a first arm disposed on a first side of the vertical body, and
a second arm disposed on a second side of the vertical body, and

a second bracket having:
a third arm, and
a fourth arm extending in an opposite direction as the third arm; and

a fastener to couple the first bracket and the second bracket together such that the first solar module is secured between the first arm and the third arm, and the second solar module is secured between the second arm and the fourth arm.

16. The mounting system of claim 15 , wherein:
the first bracket includes a protrusion disposed on the vertical body;
the second bracket includes one or more grooves; and
the protrusion engages with at least one groove of the one or more grooves.

17. The mounting system of claim 15 , wherein:
the first bracket includes a second vertical body;
the third arm is disposed a third side of the second vertical body; and
the fourth arm is disposed on a fourth side of the second vertical body.

18. The mounting system of claim 15 , wherein:
a first distance extends between a first edge of the first arm and a second edge of the second arm; and
a second distance extends between a third edge of the third arm and a fourth edge of the fourth arm, the second distance being greater than the first distance.

19. The mounting system of claim 15 , wherein:
the rail includes:
a first track, and
a second track that extends perpendicular to the first track;

the first clamp includes a first connection portion that is at least partially disposed within the first track; and
the one or more mounts include a second connection portion that is at least partially disposed within the second track.

20. The mounting system of claim 7 , wherein the connector is unattached to the rail.

Assignees

• Unirac Inc

Inventors

• Schuit Nathan
• Mayfield Jason
• Cowen December
• Womacks Darren

Classifications

• Y02B10/10

  Photovoltaic [PV] · CPC title

• F24S25/35 Primary

  by means of profiles with a cross-section defining separate supporting portions for adjacent modules · CPC title

• Y02B10/20

  Solar thermal · CPC title

• F24S25/636

  clamping by screw-threaded elements · CPC title

• F24S25/632

  Side connectors; Base connectors · CPC title