Solar panel support system

Abstract

A solar panel racking system includes a solar module and a racking assembly. The solar module includes a frame assembly and a solar panel. The frame assembly includes a frame and a frame flange extending from the frame. The racking assembly includes a torque tube and a mounting assembly. The mounting assembly includes a rail assembly, each rail assembly including a mounting rail, a clamp coupling the mounting rail to the torque tube, and a ground lock. The rail defines an interior volume, a longitudinal opening receiving the frame flange, and a second interface positioned to align with a respective one of the first interfaces. The ground lock includes a mounting flange coupled to an interior surface of the mounting rail, a locking arm extending from the mounting flange and terminating at a locking flange, and a grounding arm extending from the mounting flange and terminating at a grounding contact. The locking flange extends through the respective one of the first interfaces and the second interface. The grounding contact engages the frame flange.

Description

Technical Field

[0001] This invention relates to the field of solar energy, and more specifically to a solar panel support system. Background Technology

[0002] Solar panels are encapsulated components of photovoltaic cells. They utilize sunlight (such as photons) to generate electricity via the photovoltaic effect. Solar panels are commonly used to generate and supply power to load devices or systems. They are an environmentally friendly alternative to other energy sources such as coal, oil, or gasoline.

[0003] Solar modules (e.g., solar panels and frame assemblies including frame mounting devices) are typically mounted to bracket equipment (e.g., their rails) using fastening hardware. The solar mounting rails and fastening hardware must provide sufficient mounting to accommodate the design load and provide an electrical grounding connection for each solar module. Typical fastening hardware includes nuts, bolts and washers, rivets, or clamps. Existing fastening hardware requires additional labor and operating costs (e.g., purchasing and shipping torque wrenches, battery packs, compressors, pneumatic hoses, etc.). Furthermore, mounting clamps are expensive and require hammering onto the solar module's frame rails, increasing the likelihood of installation damage. Summary of the Invention

[0004] One embodiment relates to a solar panel mounting system. The solar panel mounting system includes a solar module and a mounting assembly. The solar module includes a frame assembly and a solar panel. The frame assembly includes a frame and a frame flange extending from the frame. The frame defines a first interface. The solar panel is supported by the frame. The mounting assembly includes a torque tube and a mounting assembly. The mounting assembly includes a first rail assembly and a second rail assembly. Each of the first and second rail assemblies includes a mounting rail, a clamp for engaging the mounting rail to the torque tube, and at least one grounding lock (e.g., one, two, etc.). The mounting rail defines an internal volume, a frame flange receiving the frame assembly such that when the frame assembly engages with the mounting assembly, the frame flange extends into a longitudinal opening in the internal volume of the mounting rail, and a second interface positioned to align with a corresponding one of the first interfaces of the frame. At least one grounding lock is disposed within the internal volume of the mounting rail. The grounding lock includes a mounting flange coupled to the inner surface of a mounting rail, a locking arm extending from the mounting flange and terminating at a locking flange, and a grounding arm extending from the mounting flange and terminating at an electrical grounding contact (e.g., toothed, capable of penetrating a coating or outer surface on the frame flange). The locking flange extends through a corresponding first interface of the frame and a second interface of the mounting rail. The electrical grounding contact is positioned to engage with a frame flange extending into the inner volume of the mounting rail to facilitate electrical grounding of the frame assembly.

[0005] A solar panel support system, comprising:

[0006] A solar module, including a solar panel and a frame assembly supporting the solar panel; and

[0007] A bracket assembly includes a support member and a mounting assembly, one end of which is fastened to the support member;

[0008] The frame assembly is slidably supported on the mounting assembly from either end of the mounting assembly, and when the frame assembly is slid onto the mounting assembly at a first position, the mounting assembly and the frame assembly are locked together.

[0009] Preferably, the mounting assembly includes two guide rail assemblies spaced apart on the support member;

[0010] The frame assembly has a pair of opposing edges spaced apart along the support member, each edge being connected to a guide rail assembly.

[0011] Preferably, the frame assembly includes a module frame and a frame catcher, the frame catcher being disposed at the bottom of the module frame;

[0012] The guide rail assembly includes a mounting rail with an internal volume. The module frame is supported on the mounting rail. The top of the internal volume has a longitudinal opening extending through its length, and the frame capture member slides in the longitudinal opening.

[0013] Preferably, the mounting rail includes:

[0014] bottom wall;

[0015] A pair of sidewalls, connected to the bottom wall and together forming the U-shaped internal volume; and

[0016] A lip is provided at one end of each sidewall away from the bottom wall, the lips on the two sidewalls are opposite each other, and the longitudinal opening is provided between the two lips.

[0017] Preferably, a frame assembly is provided on each of the two lips of the same mounting rail.

[0018] Preferably, the end of the lip that faces away from the sidewall it is connected to has a fixed flange facing the inner volume;

[0019] The frame capture component includes a tap, a contact rail, and a hook connected in sequence, with the fixing flange disposed between the tap, the contact rail, and the hook.

[0020] Preferably, the guide rail assembly further includes at least one grounding lock, one end of which is connected to the side wall, and the other end of which passes through the lip and locks the frame assembly.

[0021] Preferably, the grounding lock includes:

[0022] Locking spring arm;

[0023] The mounting end is located at the first end of the locking spring arm and can be connected to the side wall; and

[0024] A locking end is disposed at the second end of the locking spring arm, the locking end having at least one protrusion, and the frame base of the module frame and the lip edge respectively having protrusion holes that mate with each of the protrusions; and

[0025] A grounding elastic element is disposed at the second end of the locking spring arm, and the grounding elastic element is used to connect the frame capture element.

[0026] Preferably, the grounding elastic element includes:

[0027] A grounding flexible arm, with a grounding notch between it and the mounting end; and

[0028] A grounding contact portion is connected to one end of the grounding elastic arm away from the mounting end, and the grounding contact portion abuts against the contact guide rail.

[0029] Preferably, the guide rail assembly further includes two opposing tube clamps, the tube clamps comprising:

[0030] The lower arms of the two tube clamps are connected and fixed to the support member by fasteners; and

[0031] The upper arm is connected to the lower arm at an acute angle. The upper arm has an upper end portion at the end away from the lower arm. The upper end portion is snapped onto the bottom wall from any end of the internal volume.

[0032] Preferably, the lower arm is provided with a pipe interface for accommodating the lower part of the support member, and a connecting flange is provided at the end of the pipe interface away from the upper arm. The connecting flanges of the two lower arms are connected by fasteners.

[0033] Preferably, the upper end is provided with a retaining tab, and the bottom wall is provided with a retaining slot, wherein the retaining tab engages with the retaining slot.

[0034] Preferably, the upper end is also provided with a notch, and the notches of the two upper arms are joined together, so that the two upper ends extend through each other.

[0035] The beneficial effects of the present invention are as follows: the at least one grounding lock is disposed within the internal volume of the mounting rail, the at least one grounding lock includes a mounting flange, a locking arm, and a grounding arm, the mounting flange being coupled to the inner surface of the mounting rail; the locking arm extends from the mounting flange and terminates at the locking flange, the locking flange extending through a corresponding one of the first interfaces of the frame and a second interface of the mounting rail; the grounding arm extends from the mounting flange and terminates at an electrical grounding contact portion, the electrical grounding contact portion being positioned to engage with a frame flange extending into the internal volume of the mounting rail, so as to electrically ground the frame assembly.

[0036] This overview is illustrative only and is not intended to be limiting in any way. Other aspects, inventive features, and advantages of the apparatus or process described herein will become apparent from the detailed description set forth herein in conjunction with the accompanying drawings, wherein like reference numerals refer to like elements. Attached Figure Description

[0037] Figure 1 This is a perspective view of a solar panel support system according to an exemplary embodiment, the solar panel support system having (i) a support assembly including a torque tube and a mounting assembly and (ii) a solar module including a frame assembly and a solar panel.

[0038] Figure 2 This is according to an exemplary embodiment. Figure 1 Detailed perspective view of the guide rail assembly of the mounting components.

[0039] Figure 3 and Figure 4 This is according to an exemplary embodiment. Figure 2 Various detailed views of the guide rail assembly.

[0040] Figure 5 This is according to an exemplary embodiment. Figure 2 Detailed perspective view of the tube clamp of the guide rail assembly.

[0041] Figure 6 According to the exemplary embodiment, Figure 3 and Figure 4 The guide rail is connected to Figure 1 Torque tube Figure 5 Detailed perspective view of the pipe clamp.

[0042] Figure 7 This is according to an exemplary embodiment. Figure 2 Detailed perspective view of the grounding lock of the guide rail assembly.

[0043] Figure 8 It is a connection according to an exemplary embodiment. Figure 2 The guide rail assembly Figure 1Detailed cross-sectional view of the frame components of the solar module.

[0044] Figure 9 According to the exemplary embodiments and Figure 1 The frame components of the solar module are joined together. Figure 7 Detailed perspective view of the grounding lock.

[0045] Figure 10 This is for assembly according to an exemplary embodiment. Figure 1 A perspective view of the installation tools for the solar panel support system.

[0046] Figure 11 and Figure 12 The use of exemplary embodiments is shown. Figure 10 Assembly tools Figure 1 The process of building a solar panel support system. Detailed Implementation

[0047] Before turning to the accompanying drawings, which illustrate certain exemplary embodiments in detail, it should be understood that this disclosure is not limited to the details or methods set forth in the specification or shown in the drawings. It should also be understood that the terminology used herein is for descriptive purposes only and should not be considered limiting.

[0048] According to an exemplary embodiment, the solar panel system of this disclosure includes a solar panel mounting assembly that facilitates the fastener-free mounting of solar modules to a support (e.g., a torque tube, etc.). Specifically, the solar panel mounting assembly eliminates the need for conventional fasteners (e.g., rivets, bolts, etc.) or clamps to secure the solar modules to the mounting assembly for the solar modules. This fastener-free design can be cheaper, faster, and easier to install, provides a more repeatable installation process, mitigates damage that can occur during installation using designs that require fasteners or clamps, and requires fewer tools compared to conventional fastener-based designs. Few efforts in industry have been made to provide products that eliminate and / or reduce the use of fasteners to lower labor, operating, and material costs. Currently, all products on the market require multiple fasteners per solar module to secure it to the bracket. In today's solar mounting market, there are no products that allow the installation of solar modules without tools or fasteners.

[0049] like Figure 1As shown, the solar panel system, illustrated as solar panel support system 10, includes solar panel mounts, supports, or a support assembly, illustrated as support assembly 20, and a solar panel assembly, illustrated as solar module 200. Support assembly 20 includes a support (e.g., an elongated mounting support, tube, support tube, etc.), illustrated as torque tube 30, and a solar mounting module, illustrated as mounting assembly 40. Mounting assembly 40 includes a pair of mounting rail assemblies, illustrated as rail assemblies 50, spaced apart at a selected distance along torque tube 30. Rail assemblies 50 are configured to support the solar module 200 and connect it to torque tube 30. In some embodiments, support assembly 20 includes a plurality of mounting assemblies 40 and associated rail assemblies 50 spaced apart along torque tube 30 to support a plurality of solar modules 200. In some embodiments, adjacent solar modules 200 share a common guide rail assembly 50 along their adjacent edges (e.g., the first solar module 200 is supported by the first guide rail assembly 50 and the second guide rail assembly 50, the second solar module 200 is supported by the second guide rail assembly 50 and the third guide rail assembly 50, etc.).

[0050] like Figure 1 As shown, the solar module 200 includes a photovoltaic module, shown as a solar panel 202, which is supported by a peripheral frame assembly, shown as a frame assembly 210. The frame assembly 210 facilitates the connection of the solar panel 202 to a rail assembly 50 of the mounting assembly 40. According to an exemplary embodiment, the solar panel 202 includes a plurality of photovoltaic cells configured to receive and convert solar energy (e.g., light energy) from a light source (e.g., the sun) to generate electrical power. The generated electrical power can be provided to charge and / or supply power to a load. The power output of the solar panel support system 10 can be related to the surface area of ​​its solar panel 202 and / or the relative orientation between the solar panel support system 10 and the light source.

[0051] like Figure 2 As shown, each guide rail assembly 50 includes a guide rail shown as mounting guide rail 60, a pair of connecting members shown as pipe clamp 100, and a pair of locking members shown as grounding lock 140. Figure 3 As shown, the mounting rail 60 has a first end shown as end 62 and an opposing second end shown as end 64. Figure 3 and Figure 4 As shown, the mounting rail 60 has an outer wall comprising a first plate shown as a bottom wall 66 and a pair of side plates shown as side walls 68, which extend along opposite edges of the bottom wall 66 and upward therefrom. The bottom wall 66 and side walls 68 together define an internal chamber shown as an internal volume 70. Figure 3 and Figure 4 In the exemplary embodiment shown, the bottom wall 66 and side walls 68 of the outer wall define a generally U-shaped profile for the mounting rail 60. In other embodiments, the outer wall of the mounting rail 60 has different shapes.

[0052] like Figure 3 and Figure 4 As shown, the end of the sidewall 68 opposite the bottom wall 66 terminates at an edge shown as a lip 72. The lips 72 extend or project inward toward each other and terminate at a curved flange shown as a fixed flange 74, which curls rearward toward the sidewall 68. Figure 4 As shown, the sidewall 68, lip 72, and fixing flange 74 together define a pair of channels, shown as channels 76, within the internal volume 70. Figure 3 and Figure 4 As shown, the lips 72 are spaced apart by a distance, thereby defining a longitudinal opening shown as a slit 78 between them, which provides passage to the internal volume 70 of the mounting rail 60.

[0053] like Figure 4 and 6 As shown, the bottom wall 66 of the mounting rail 60 defines a plurality of openings shown as retaining slots 80. A first retaining slot 80 is positioned near a first sidewall of the sidewalls 68 and closer to the end 62 of the mounting rail 60. A second retaining slot 80 is positioned near a second sidewall of the sidewalls 68 and closer to the end 64 of the mounting rail 60. Figure 3 As shown, sidewall 68 includes a plurality of mounting interfaces defining a plurality of mounting orifices shown as mounting holes 82. A first mounting interface, including a first set of mounting holes 82, is positioned along a first sidewall of sidewall 68 near the end 62 of mounting guide 60. A second mounting interface, including a second set of mounting holes 82, is positioned along a second sidewall of sidewall 68 near the end 64 of mounting guide 60. Figure 3 As shown, each of the lips 72 includes a locking interface that defines a plurality of locking apertures, shown as tab holes 84, which are arranged in series along the lip 72 at or near the center of the mounting rail 60. Although shown to define three tab holes 84, in other embodiments, the lip 72 defines a different number of tab holes 84 (e.g., one, two, four, etc.).

[0054] like Figure 5 As shown, the pipe clamp 100 includes a first end shown as a lower end 102, a second end shown as an upper end 104, a first portion shown as a lower arm 106 extending from the lower end 102, and a second portion shown as an upper arm 108 extending from the lower arm 106 to the upper end 104. Figure 5In the exemplary embodiment shown, the upper arm 108 extends horizontally or substantially horizontally, and the lower arm 106 extends downward from the upper arm 108 at an acute angle θ (e.g., less than 90 degrees, such as 30 degrees, 45 degrees, 60 degrees, etc.), such that the lower end 102 and the upper end 104 extend in the same direction.

[0055] like Figure 5 As shown, the lower arm 106 defines a first interface, shown as a pipe interface 110, and terminates at a flange, shown as a clamping flange 112, positioned at the lower end 102. The clamping flange 112 defines an orifice, shown as a connecting hole 114. The upper arm 108 defines a notch, shown as a notch 116, positioned at the upper end 104 such that the upper arm 108 is narrower or thinner at the upper end 104 than at the opposite end of the upper arm 108 connecting to the lower arm 106. The upper arm 108 terminates at a retainer, shown as a retaining tab 118, extending downward from the upper end 104 of the upper arm 108.

[0056] like Figure 6 As shown, two of the pipe clamps 100 are configured to cooperatively connect one of the mounting rails 60 to the torque tube 30. The upper end 104 of the pipe clamp 100 abuts against the mounting rail 60 to hold or secure the outer surface of the bottom wall 66 against the upper portion 34 of the torque tube 30, while the lower arm 106 clamps onto the lower portion 32 of the torque tube 30 to connect or secure the rail assembly 50 to the torque tube 30. Figure 6 As shown, the pipe interface 110 of the lower arm 106 of the pipe clamp 100 is shaped (e.g., bent, angled, etc.) to receive (e.g., mat with, engage with, receive, etc.) the lower portion 32 of the torque tube 30. The lower ends 102 of the pipe clamp 100 are aligned such that the clamp flanges 112 can be secured together using fasteners (e.g., bolts and nuts, rivets, etc.) extending through the connecting holes 114 of the clamp flanges 112. The upper arms 108 extend into the internal volume 70 of the mounting rail 60 through opposite ends (i.e., ends 62 and 64) and along the inner surface of the bottom wall 66 of the mounting rail 60. The recesses 116 of the upper arms 108 abut each other such that the upper ends 104 of the upper arms 108 extend through each other, and each of the retaining tabs 118 extends into a corresponding retaining slot 80 defined by the bottom wall 66 of the mounting rail 60. In other embodiments, the upper arm 108 does not define a notch 116 such that the upper ends 104 do not extend through each other.

[0057] like Figure 7As shown, the grounding lock 140 includes a main body portion shown as a locking spring arm 142, having a first end portion shown as a mounting end 143 and an opposing second end portion shown as a locking end 144. The grounding lock 140 includes a mounting interface shown as a mounting flange 146 and a grounding element shown as a grounding spring 150, positioned at the mounting end 143 of the locking spring arm 142. The mounting flange 146 extends vertically downward from the mounting end 143 of the locking spring arm 142. The mounting flange 146 includes a mounting interface defining a plurality of orifices shown as mounting holes 148.

[0058] like Figure 7 As shown, the grounding spring 150 includes a biasing element shown as a grounding spring arm 152 and an electrical grounding interface shown as a grounding contact 154. The grounding spring arm 152 is defined by the remainder of the mounting end 143 of the locking spring arm 142 and is substantially separated from the remainder of the mounting end 143 of the locking spring arm 142 by a cut shown as a grounding cutout 156, such that the grounding spring arm 152 is cantilevered. The grounding contact 154 is positioned at the free end of the grounding spring arm 152. Figure 7 In the exemplary embodiment shown, the grounding contact portion 154 has a plurality of sharp teeth.

[0059] like Figure 7 As shown, the grounding lock 140 includes a locking interface, shown as a locking flange 158, which is positioned at the locking end 144 of the locking spring arm 142. The locking flange 158 extends vertically upward from the locking end 144 of the locking spring arm 142. The locking flange 158 includes a locking interface defining a plurality of tabs (shown as outer tab 160 and inner tab 162). Figure 7 In the exemplary embodiment shown, the outer tab 160 has an angled or tapered profile. As... Figure 7 As shown, the locking flange 158 includes two outer tabs 160 and a single inner tab 162. In other embodiments, the locking flange 158 includes a plurality of inner tabs 162. In yet another embodiment, the locking flange 158 does not include an inner tab 162.

[0060] like Figure 8As shown, a grounding lock 140 is positioned within the internal volume 70 of a mounting rail 60. Each respective grounding lock 140 is coupled to the inner surface of one of the sidewalls 68 of the mounting rail 60. Specifically, the mounting flange 146 of each of the grounding locks 140 is coupled to the inner surface of one of the sidewalls 68 by aligning the mounting hole 148 of the mounting flange 146 with the mounting hole 82 of the sidewall 68 and securing the mounting flange 146, and thus the grounding lock 140, to the sidewall 68 of the mounting rail 60 using fasteners (e.g., bolts, rivets, etc.). In other embodiments, the mounting flange 146 is otherwise coupled (e.g., welded, bonded, clamped, held, held, etc.) to the inner surface of the sidewall 68. In some embodiments, the spring arm 142 of the grounding lock 140 is rigid (that is, it does not function like a spring or flexure as described herein). In such an embodiment, the mounting flange 146 can be resiliently mounted to the sidewall 68 of the mounting rail 60 such that when the locking flange 158 is engaged by the solar cell module 200, the grounding lock 140 pivots about its connection to the sidewall 68, as described in more detail herein.

[0061] like Figure 8 As shown, the locking flange 158 of each grounding lock 140 extends vertically upward from the locking end 144 of the locking spring arm 142, such that the outer tab 160 and the inner tab 162 (i) protrude into the channel 76 defined by the sidewall 68 of the mounting rail 60, the lip 72, and the fixing flange 74, and (ii) pass through the tab hole 84 defined in the associated lip 72. Therefore, the locking end 144 of the locking spring arm 142 is a free end, making the locking spring arm 142 cantilevered.

[0062] like Figure 8 and Figure 9 As shown, the frame assembly 210 of the solar module 200 includes a first frame portion shown as a module frame 220. The module frame 220 has a base shown as a frame base 222 and a peripheral sidewall shown as a frame sidewall 224 extending around the periphery of the frame base 222. The frame base 222 of the module frame 220 includes a locking interface defining a plurality of orifices shown as tab holes 226, which are arranged in series along opposite edges of the module frame 220 (e.g., along opposite lateral edges, along opposite longitudinal edges, etc.).

[0063] like Figure 8As shown, the frame assembly 210 of the solar module 200 includes a second frame portion or flange, shown as a frame catcher 230, which extends along opposite edges of the module frame 220 (e.g., along opposite lateral edges, along opposite longitudinal edges, etc.). The frame catcher 230 has a first portion shown as a tap 232 extending downward from the frame base 222; a second portion shown as a contact rail 234 extending inward from the tap 232 toward the center of the solar module 200; and a third portion shown as a hook 236 extending upward from the end of the contact rail 234.

[0064] like Figure 8 and Figure 9 As shown, when the frame assembly 210 of the solar module 200 is connected to the rail assembly 50, (i) the frame base 222 rests along the lip 72, (ii) the tap 232 of the frame catch 230 extends through the slit 78 defined between the lips 72 of the mounting rail 60, (iii) the contact rail 234 of the frame catch 230 engages with the teeth of the ground contact portion 154 of the grounding spring 150 of the grounding lock 140, and (iv) the frame catch 230... Hook 236 extends into channel 76 and abuts against fixing flange 74 of lip 72, such that fixing flange 74 is surrounded by tap 232 of frame capture 230, contact rail 234 and hook 236, and (v) tab hole 226 of frame base 222 is aligned with tab hole 84 of lip 72 of mounting rail 60, such that outer tab 160 and inner tab 162 of locking flange 158 of grounding lock 140 protrude through tab hole 84 and tab hole 226.

[0065] According to an exemplary embodiment, the solar module 200 is mounted onto the bracket assembly 20 as follows. First, the mounting assembly 40 is mounted onto the torque tube 30 by connecting two guide rail assemblies 50 at a selected distance to accommodate the solar module 200 (i.e., based on the width of the solar module 200). Second, frame catchers 230 extending from opposite sides of the module frame 220 of the frame assembly 210 are inserted into the internal volume 70 and the slit 78 through one of the ends 62 or 64 of each of the mounting guide rails 60 of the mounting assembly 40, such that hooks 236 slide into the channel 76 and engage with the retaining flange 74. Third, the solar module 200 slides (e.g., is pushed, pulled, etc.) along the lip 72 of the mounting rail 60 of the mounting assembly 40 until the frame assembly 210 of the solar module 200 engages with the grounding lock 140 of the rail assembly 50 to lock and hold the solar module 200 in place and to ground the solar module 200 without the use of tools or fasteners (i.e., the mounting assembly 40 and the solar module 200 have a fastener-free connection). The interaction between the grounding lock 140 of the mounting assembly 40 and the frame assembly 210 of the solar module 200 will be described in more detail herein, specifically (i) the locking interaction between the grounding lock 140 and the frame assembly 210, and (ii) the grounding interaction between the grounding lock 140 and the frame assembly 210.

[0066] As the frame assembly 210 slides along the mounting rail 60, the leading edge of the frame sidewall 224 of the module frame 220 interacts with the tapered profile of one of the outer tabs 160 of the locking flanges 158 of each of the grounding locks 140 (depending on which end of the mounting rail 60 the solar module 200 is mounted from), the outer tab protruding through the tab hole 84 of the lip 72 of the mounting rail 60. The force of the frame sidewall 224 of the module frame 220 against the tapered profile of the outer tab 160 causes the locking spring arm 142 to flex or bend (or pivot in the case of elastic mounting to the mounting rail 60), such that the outer tab 160 and inner tab 162 of the locking flange 158 retract into the tab hole 84 of the mounting rail 60 of the mounting assembly 40, and the frame assembly 210 can continue to slide along the mounting rail 60. Then, when the tab hole 226 defined by the frame base 222 of the module frame 220 aligns with the tab hole 84 defined by the lip 72 of the mounting rail 60, the locking spring arm 142 flexes rearward and biases the locking flange 158 back to their initial position, such that the outer tab 160 and inner tab 162 of the locking flange 158 protrude through the tab hole 84 of the mounting rail 60 and the tab hole 226 of the frame base 222 of the module frame 220. Thus, the combination of the locking flange 158 and the frame catch 230 secures and locks the solar module 200 to the mounting assembly 40. Specifically, (i) the interaction between the locking flange 158 and the module frame 220 prevents the solar module 200 from sliding along the mounting rail 60 of the mounting assembly 40, and (ii) the interaction between the hook 236 of the frame catch 230 and the fixing flange 74 of the lip 72 of the mounting rail 60 prevents the solar module 200 from being lifted away from the mounting rail 60 of the mounting assembly 40.

[0067] Furthermore, as the frame assembly 210 slides along the mounting rail 60, the contact rail 234 of the frame catcher 230 engages with the ground contact portion 154 of the grounding spring 150 of the grounding lock 140. Specifically, the grounding spring arm 152 flexes or bends when the contact rail 234 engages with the teeth of the ground contact portion 154, and then biases or presses the teeth of the ground contact portion 154 into the surface of the contact rail 234. This biased contact causes the teeth of the ground contact portion 154 to cut through any coating, corrosion, or anodizing along the surface of the contact rail 234 to provide sufficient contact between the ground contact portion 154 and the underlying material of the contact rail 234, thereby facilitating the electrical grounding of the solar module 200.

[0068] like Figures 10 to 12As shown, the installer can use the spacer and installation tool shown as module installation tool 300 to properly space the guide rail assembly 50 of the mounting assembly 40 along the torque tube 30 to accommodate the solar module 200 and guide the solar module 200 to engage with the mounting assembly 40. Figure 10 As shown, the module mounting tool 300 includes a lateral member shown as a crossbar 302, having a first end shown as a left end 304 and an opposing second end shown as a right end 306. The module mounting tool 300 includes a pair of end assemblies shown as guide assemblies 308, one of which is coupled to each of the left end 304 and right end 306 of the crossbar 302. Each of the guide assemblies 308 includes a housing shown as a coupling receiver 310 that receives and / or is coupled to the crossbar 302. In some embodiments, the coupling receiver 310 may be repositioned along the crossbar 302 (e.g., slidable, translatable, etc.) (e.g., the end of the crossbar 302 may selectively extend or retract within the coupling receiver 310, etc.) to adjust the width w of the module mounting tool 300 to accommodate solar modules 200 of varying widths. In other embodiments, the width w of the module mounting tool 300 is fixed. In such an embodiment, multiple module mounting tools 300 can be manufactured to accommodate solar modules 200 of different widths. For example... Figure 10 As shown, each of the guide assemblies 308 also includes a guide, shown as a guide rail 312, which is coupled to a free end of the coupling receiver 310 opposite to the end that receives or is coupled to the crossbar 302. Each of the guide rails 312 defines a slot shown as a frame channel 314. The frame channel 314 is configured (e.g., shaped, sized, constructed, etc.) to receive and guide the frame assembly 210 of the solar module 200.

[0069] like Figure 11 As shown, the dimensions of the module installation tool 300 can be redefined to correspond to the width of the frame assembly 210 of the solar module 200, or a module installation tool 300 of appropriate size can be selected based on the width of the frame assembly 210 of the solar module 200. For example... Figure 12As shown, the guide rail 312 of the module mounting tool 300 can then be inserted into the slit 78 and internal volume 70 of the mounting rail 60 of the rail assembly 50 of the mounting assembly 40 to space the rail assemblies 50 along the torque tube 30, which will accommodate the frame assembly 210 of the solar module 200. Once the rail assemblies 50 are properly spaced, the tube clamp 100 can be tightened to secure the rail assemblies 50 in place. The frame assembly 210 can then be inserted into the frame channel 314 of the guide rail 312 to lock and ground the frame assembly 210 to the rail assembly 50, as described herein. According to the exemplary embodiment, compared to typical solar installation techniques using conventional fastening hardware, the mounting assembly 40 and the module mounting tool 300 reduce labor time and costs, reduce the use of conventional fastening hardware, eliminate the need for expensive tools or equipment, improve installation quality, and provide an easily repeatable installation process. Although the installation of the solar module 200 and the bracket assembly 20 is disclosed herein as being performed using the module installation tool 300, it should be understood that the installation can be performed without using the module installation tool 300.

[0070] As used herein with respect to numerical ranges, the terms “approximately,” “about,” “substantially,” and similar terms generally indicate + / 10% of the disclosed value, unless otherwise stated. As used herein with respect to structural features (e.g., descriptions of shape, size, orientation, direction, relative position, etc.), the terms “approximately,” “about,” “substantially,” and similar terms are intended to cover minor variations in structural aspects that may result from, for example, manufacturing or assembly processes, and are intended to have a broad meaning consistent with usage generally accepted by one of ordinary skill in the art to which the subject matter of this disclosure pertains. Therefore, these terms should be interpreted as indicating that non-substantial or insignificant modifications or alterations to the described and claimed subject matter are considered to be within the scope of the disclosure as set forth in the appended claims.

[0071] It should be noted that the terms “exemplary” and variations thereof, as used herein to describe various embodiments, are intended to indicate possible examples, representations, or illustrations of possible embodiments (and these terms are not intended to mean that these embodiments are necessarily very or most advanced examples).

[0072] As used herein, the term "connection" and its variations refer to two components that are directly or indirectly linked to each other. Such a connection can be static (e.g., permanent or fixed) or movable (e.g., removable or releasable). This connection can be achieved using two components directly connected to each other, where the two components are connected to each other using separate insert members and any additional intermediate members connected to each other, or where the two components are connected to each other using insert members that are integrally formed with one of the two components into a single monolithic entity. If "connection" or its variations are modified by the additional term (e.g., direct connection), the general definition of "connection" provided above is modified by the simple linguistic meaning of the additional term (e.g., "direct connection" refers to the connection of two components without any separate insert members), resulting in a narrower definition than the general definition of "connection" provided above. Such a connection can be mechanical, electrical, or fluid.

[0073] The positions of elements mentioned herein (e.g., "top", "bottom", "above", "below") are used only to describe the orientation of the various elements in the figures. It should be noted that the orientations of the various elements may differ according to other exemplary embodiments, and such variations are intended to be covered by this disclosure.

[0074] It is important to note that the construction and arrangement of the solar panel support system 10 and its components (e.g., support assembly 20, mounting assembly 40, rail assembly 50, solar module 200, frame assembly 210, etc.) shown in the various exemplary embodiments are merely illustrative. Additionally, any element disclosed in one embodiment may be combined with or utilized in any other embodiment disclosed herein.

Claims

1. A solar panel support system, comprising: Solar module, the solar module comprising: A framework component, the framework component having: The framework that limits the first interface; and A frame flange extending from the frame; and Solar panels supported by the frame; and The support assembly includes: Torque tube; and The mounting assembly includes a first guide rail assembly and a second guide rail assembly, each of the first guide rail assembly and the second guide rail assembly comprising: Mounting rail, wherein the mounting rail is defined as follows: Internal volume; A longitudinal opening receiving a frame flange of the frame assembly such that, when the frame assembly is engaged with the mounting assembly, the frame flange extends into the internal volume of the mounting guide; and A second interface, which is positioned to be aligned with a corresponding one of the first interfaces of the frame; A clamp that connects the mounting guide rail to the torque tube; and At least one grounding lock, wherein the at least one grounding lock is disposed within the internal volume of the mounting rail, the at least one grounding lock comprising: A mounting flange is attached to the inner surface of the mounting guide rail; A locking arm extending from and terminating at the mounting flange, the locking flange extending through a corresponding first interface of the frame and a second interface of the mounting rail; and A grounding arm extends from the mounting flange and terminates at an electrical grounding contact, which is positioned to engage with a frame flange extending into the internal volume of the mounting rail to facilitate electrical grounding of the frame assembly.

2. A solar panel support system, characterized in that, include: The solar module (200) includes a solar panel (202) and a frame assembly (210) supporting the solar panel (202). as well as A bracket assembly (20) includes a support member and a mounting assembly (40). One end of the mounting assembly (40) is fastened to the support member. The mounting assembly (40) includes two guide rail assemblies (50) spaced apart on the support member. The guide rail assembly (50) includes a mounting rail (60) and at least one grounding lock (140). The mounting rail (60) includes a bottom wall (66), a pair of side walls (68), and a lip (72). One end of the grounding lock (140) is connected to the side wall (68), and the other end of the grounding lock (140) passes through the lip (72) and locks the frame assembly (210). The grounding lock (140) includes a locking end (144) and a grounding elastic element (150). The locking end (144) is provided with at least one protrusion. The frame assembly (210) and the lip (72) are respectively provided with protrusion holes that cooperate with each of the protrusions. The grounding elastic element (150) is connected to the frame assembly (210). The frame assembly (210) is slidably supported on the mounting assembly (40) from either end of the mounting assembly (40), and when the frame assembly (210) is slid onto the mounting assembly (40) at a first position, the mounting assembly (40) and the frame assembly (210) are locked together.

3. The solar panel support system according to claim 2, characterized in that, The frame assembly (210) has a pair of opposing edges spaced apart along the support member, each edge being connected to a guide rail assembly (50).

4. The solar panel support system according to claim 3, characterized in that, The frame assembly (210) includes a module frame (220) and a frame catch (230), the frame catch (230) being disposed at the bottom of the module frame (220); The mounting rail (60) has an internal volume (70), the module frame (220) is supported on the mounting rail (60), the top of the internal volume (70) has a longitudinal opening (78) extending through its length, and the frame capture member (230) slides in the longitudinal opening (78).

5. The solar panel support system according to claim 4, characterized in that, A pair of sidewalls (68) are connected to the bottom wall (66) and together form the U-shaped internal volume (70); the lip (72) is disposed at one end of each sidewall (68) away from the bottom wall (66), the lips (72) on the two sidewalls (68) are opposite to each other, and the longitudinal opening (78) is disposed between the two lips (72).

6. The solar panel support system according to claim 5, characterized in that, Each of the two lips (72) of the same mounting rail (60) is provided with a frame assembly (210).

7. The solar panel support system according to claim 5, characterized in that, The lip (72) has a fixed flange (74) facing the inner volume (70) at one end away from the side wall (68) to which it is connected. The frame capture component (230) includes a tap (232), a contact rail (234), and a hook (236) connected in sequence, and the fixing flange (74) is disposed between the tap (232), the contact rail (234), and the hook (236).

8. The solar panel support system according to claim 7, characterized in that, The grounding lock (140) also includes: Locking spring arm (142); The mounting end (143) is located at the first end of the locking spring arm (142) and can be connected to the side wall (68). The locking end (144) is disposed at the second end of the locking spring arm (142); the grounding elastic element (150) is disposed at the second end of the locking spring arm (142), and the grounding elastic element (150) is used to connect the frame capture element (230).

9. The solar panel support system according to claim 8, characterized in that, The grounding elastic element (150) includes: A grounding flexible arm (152) has a grounding cutout (156) between it and the mounting end (143); and A grounding contact (154) is connected to one end of the grounding elastic arm (152) away from the mounting end (143), and the grounding contact (154) abuts against the contact rail (234).

10. The solar panel support system according to claim 4, characterized in that, The guide rail assembly (50) also includes two opposing tube clamps (100), each tube clamp (100) comprising: The lower arms (106) of the two tube clamps (100) are connected and fixed to the support member by fasteners; and The upper arm (108) is connected to the lower arm (106) at an acute angle. The upper arm (108) has an upper end (104) at the end away from the lower arm (106). The upper end (104) is snapped onto the bottom wall (66) from any end of the internal volume (70).

11. The solar panel support system according to claim 10, characterized in that, The lower arm (106) is provided with a pipe interface (110) for accommodating the lower part (32) of the support member. The end of the pipe interface (110) away from the upper arm (108) is provided with a connecting flange (112). The connecting flanges (112) of the two lower arms (106) are connected by fasteners.

12. The solar panel support system according to claim 10, characterized in that, The upper end (104) is provided with a retaining tab (118), and the bottom wall (66) is provided with a retaining slot (80). The retaining tab (118) is engaged with the retaining slot (80).

13. The solar panel support system according to claim 12, characterized in that, The upper end (104) is also provided with a notch (116), and the notches (116) of the two upper arms (108) are joined together, so that the two upper ends (104) extend through each other.

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