Mounting system for mounting solar panel modules

Patent metadata

Field	Value
Publication number	US-2024421752-A1
Application number	US-202418815500-A
Country	US
Kind code	A1
Filing date	Aug 26, 2024
Priority date	Mar 17, 2021
Publication date	Dec 19, 2024
Grant date	—

Abstract

A mounting system includes a base to mount to a surface, a mounting bracket to mount over the base and to the surface, a clamp for attaching to the mounting bracket and securing a rail segment, and a bonding clamp to mount to the rail segment and secure a solar panel module thereto.

First claim

1 .- 20 . (canceled)

21 . A rail system comprising:
a rail segment including:
a first vertical wall including:
a first inner groove extending along a top end of the first vertical wall, and
a second inner groove extending along the top end of the first vertical wall such that the second inner groove is laterally adjacent to the first inner groove, the first inner groove being more proximate to the first vertical wall than the second inner groove, and the second inner groove being configured to receive a first portion of a connection member,

a second vertical wall adjacent to the first vertical wall, the second vertical wall including:
a third inner groove extending along a top end of the second vertical wall, and
a fourth inner groove extending along the top end of the second vertical wall such that the fourth inner groove is laterally adjacent to the third inner groove, the third inner groove being more proximate to the second vertical wall than the fourth inner groove, and the fourth inner groove being configured to receive a second portion of the connection member, and

a base extending in a direction transverse to the first vertical wall and the second vertical wall, the base being integrally formed with a bottom portion of the first vertical wall and a bottom portion of the second vertical wall.

22 . The rail system according to claim 21 , wherein:
the rail segment is a first rail segment, and the rail system further comprises:
a second rail segment;
a splice rail configured to connect the first rail segment to the second rail segment, the splice rail including:
a horizontal base integrally formed with:
a first vertical sidewall that projects transversely from the horizontal base, and
a second vertical sidewall that projects transversely from the horizontal base; and

a fastener that is retainable in the horizontal base of the splice rail such that a head of the fastener is disposed between the first vertical sidewall of the splice rail and the second vertical sidewall of the splice rail and disposed on top of a surface of the horizontal base of the splice rail.

23 . The rail system according to claim 22 , wherein the fastener is retainable in the horizontal base of the first rail segment such that a tip of the fastener extends past an outside surface of the horizontal base of the first rail segment.

24 . The rail system according to claim 22 , wherein:
the fastener is a first fastener retainable at a first end of the horizontal base of the splice rail, and the splice rail further includes a second fastener retainable at a second end of the horizontal base of the splice rail that is opposite the first end of the horizontal base of the splice rail, such that a head of the second fastener is disposed between the first vertical sidewall of the splice rail and the second vertical sidewall of the splice rail and disposed on the top of the surface of the horizontal base of the splice rail.

25 . The rail system according to claim 21 , further comprising the connection member, the connection member including:
a rail nut at a first end of the connection member, the rail nut configured to engage with the second inner groove and the fourth inner groove, and a bonding clamp at a second end of the connection member opposite the first end, the bonding clamp configured to engage with a solar panel module.

26 . The rail system according to claim 21 , wherein:
the first vertical wall further includes:
an outside surface,
an inside surface, and
a first protrusion extending from the outside surface of the first vertical wall at a bottom portion of the first vertical wall; and
the second vertical wall further includes:
an outside surface,
an inside surface, and
a second protrusion extending from the outside surface of the second vertical wall at a bottom portion of the second vertical wall.

27 . The rail system according to claim 21 , wherein the rail segment further includes a first protrusion and a second protrusion, and
wherein the rail system further comprises:
a mounting bracket; and
a clamp configured to secure the rail segment to the mounting bracket, the clamp including:
a vertical clamp wall having a wall groove,
a horizontal flange extending from the vertical clamp wall,
a web section extending from the horizontal flange, and
a lip groove disposed in a lip extending from the web section,

wherein the clamp is configured such that the first protrusion of the rail segment is received by the lip groove and the horizontal flange is urged to displace the lip groove such that the second protrusion of the rail segment is received by the wall groove.

28 . The rail system according to claim 21 , further comprising:
a clamp configured to receive the rail segment; and a mounting bracket configured to secure the clamp, the mounting bracket including:
a bracket base,
a footing portion shaped to straddle across at least a portion of the bracket base,
a first foot extending from a first side of the footing portion,
a second foot extending from a second side of the footing portion,
a through-hole extending through the footing portion and aligning with an opening of the base, and
a stanchion extending from the footing portion, the stanchion having a slot to receive a fastener for securing the clamp to the mounting bracket.

29 . A rail system comprising:
a rail segment including:
a first wall including:
a first inner groove extending along a top end of the first wall, and
a second inner groove extending along the top end of the first wall, the second inner groove being laterally adjacent to the first inner groove,

a second wall adjacent to the first wall, the second wall having:
a third inner groove extending along a top end of the second wall, and
a fourth inner groove extending along the top end of the second wall, the fourth inner groove being laterally adjacent to the third inner groove, and

a base extending in a direction transverse to the first wall and the second wall.

30 . The rail system according to claim 29 , wherein:
the first inner groove is configured to receive a first portion of a splice rail, the second inner groove is configured to receive a first portion of a connection member, the third inner groove is configured to receive a second portion of the splice rail, and the fourth inner groove is configured to receive a second portion of the connection member.

31 . The rail system according to claim 29 , wherein:
the first wall further includes:
an outside surface,
an inside surface, and
a first protrusion extending from the outside surface of the first wall at a bottom portion of the first wall, and
the second wall further includes:
an outside surface,
an inside surface, and
a second protrusion extending from the outside surface of the second wall at a bottom portion of the second wall.

32 . The rail system according to claim 29 , wherein:
the rail segment is a first rail segment, and the rail system further comprises:
a second rail segment;
a splice rail configured to connect the first rail segment to the second rail segment, the splice rail including:
a horizontal base integrally formed with:
a first vertical sidewall that projects transversely from the horizontal base, and
a second vertical sidewall that projects transversely from the horizontal base; and

a fastener that is retainable in the horizontal base of the splice rail such that a head of the fastener is disposed between the first vertical sidewall of the splice rail and the second vertical sidewall of the splice rail and disposed on top of a surface of the horizo

Assignees

• Unirac Inc

Inventors

• Neal Jonathan
• Ganshaw Todd
• Schuit Nathan

Classifications

• F24S25/61

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

• H02S30/10

  Frame structures · CPC title

• F16B2/06

  external, i.e. with contracting action (F16B2/14 - F16B2/18 take precedence) · CPC title

• F16B7/0493

  forming a crossed-over connection · CPC title

• F16B7/0473

  with hook-like parts gripping, e.g. by expanding, behind the flanges of a profile · CPC title