Solar module mounting bracket assembly

Abstract

A solar module mounting bracket assembly includes a rail configured to support a solar module thereon and a pair of supports. The supports each have a first end portion movably coupled to the rail. The support is movable relative to the rail between a collapsed configuration and an expanded configuration. In the deployed configuration, the supports cooperatively define a channel sized for receiving a frame member.

Description

[0001] Divisional Application Information

[0002] This application is a divisional application of the invention patent application with the application date of August 29, 2019, application number 201980056120.4, and invention name “Solar module mounting bracket assembly”. Background Art 1. Technical Field

[0003] The present invention generally relates to mounting brackets. More particularly, the present invention relates to mounting brackets for coupling solar modules to a frame.

[0004] 2. Related technical background

[0005] A solar mount system is provided to support one or more photovoltaic ("PV") module arrays and couple the arrays to a frame, such as, for example, a plurality of parallel-oriented rotatable torque tubes. The solar mount system is designed to maintain the PV modules in a fixed position relative to a torque tube while the torque tube rotates during solar tracking.

[0006] Solar mounting systems can add significant costs to solar power generation systems for at least two reasons. First, the components themselves are expensive to manufacture, transport, and install. Second, installation and operation are expensive because they require time and skilled operators to perform quality control measures on site. Therefore, there is a need for PV mounting systems that are easier and less expensive to package, transport, and install. Summary of the invention

[0007] In one aspect of the present invention, a solar module mounting bracket assembly is provided. The solar module mounting bracket assembly includes: a rail configured to support a solar module thereon; and a pair of supports, each having a first end movably coupled to the rail. The supports are movable relative to the rail between a folded configuration and an unfolded configuration. In the unfolded configuration, the supports cooperatively define a channel sized to receive a frame member.

[0008] In various aspects, the supports can be parallel to the rails in the folded configuration and perpendicular to the rails in the unfolded configuration.

[0009] In various aspects, the solar module mounting bracket assembly can have a substantially linear shape when the support is in the folded configuration. In further aspects, the solar module mounting bracket assembly can have a substantially triangular shape when the support is in the deployed configuration.

[0010] In various aspects, the solar module mounting bracket assembly can further include a fastener configured to attach to the second end of each of the supports to secure the supports in the deployed configuration.

[0011] In various aspects, the solar module mounting bracket assembly can further include a pair of truss arms. Each of the truss arms can include a first end movably coupled to a respective second end of the pair of supports, and a second end slidably coupled to a respective first and second end of the rail.

[0012] In various aspects, the truss arm can be configured to move relative to the rail and the support between a folded configuration in which the truss arm is parallel to the rail and the pair of supports and a deployed configuration in which the truss arm extends perpendicularly relative to the rail.

[0013] In various aspects, the second end of each of the truss arms can be configured to slide away from a center portion of the rail when the pair of truss arms are moved toward the folded configuration.

[0014] In various aspects, the second end of each of the truss arms can be moved along the rail from an inward position to an outward position. In the inward position, the truss arms can be in the deployed configuration, and in the outward position, the truss arms can be in the folded configuration.

[0015] In aspects, each of the first and second ends of the rail can define a track through which the respective second end of the truss arm slides.

[0016] In various aspects, the solar module mounting bracket assembly can further include a fastener assembly coupled to the second end of the first of the truss arms. The fastener assembly can be configured to selectively secure the second end of the first truss arm in position on the track of the rail.

[0017] In various aspects, the fastener assembly may include a pair of washers disposed on opposite sides of the rail, and a fastener coupling the pair of washers to each other. The fastener may be configured to adjust the distance between the washers. At least one of the washers has a pair of first and second lugs extending therefrom. The first and second lugs may be configured to be received in corresponding slots defined in the rail.

[0018] In various aspects, the first washer can further include a third lug extending therefrom.The third lug can be disposed in the track of the rail to guide the fastener assembly through the track.

[0019] In various aspects, the solar module mounting bracket assembly can further include a protrusion that protrudes downward relative to the bottom side of the rail. When the support is in the deployed configuration, the protrusion can extend into the channel defined by the support.

[0020] In various aspects, each of the supports can have a concave inner surface such that the channel cooperatively defined by the first and second supports has a circular shape.

[0021] In various aspects, the solar module mounting bracket assembly can further include a plurality of coupling devices disposed on an upper side of the rail. The coupling devices can be configured to secure a solar module to the rail.

[0022] In a further aspect of the present invention, a PV module mounting bracket assembly is provided, comprising a rail, a pair of supports, a fastener, and a pair of truss arms. The rail is configured to support a PV module thereon and has a first end, a center portion, and a second end. Each of the supports comprises a first end movably coupled to the center portion of the rail, and a second end. The supports are movable relative to the rail between a folded configuration and an unfolded configuration. In the folded configuration, the supports are parallel to the rail, and in the unfolded configuration, the supports are perpendicular to the rail and cooperatively define a channel sized to receive a frame member. The fastener is configured to attach to the second end of each of the supports to secure the supports in the unfolded configuration. Each of the truss arms comprises a first end coupled to the respective second ends of the pair of supports, and a second end slidably coupled to the respective first and second ends of the rail.

[0023] Further details, advantages and aspects of exemplary embodiments of the invention are described in more detail below with reference to the accompanying drawings.

[0024] As used herein, the terms parallel and perpendicular are understood to encompass relative configurations ranging from true parallel and true perpendicular to substantially parallel and substantially perpendicular up to about + or -30 degrees. BRIEF DESCRIPTION OF THE DRAWINGS

[0025] Embodiments of the present invention are described herein with reference to the accompanying drawings, in which:

[0026] Figure 1 is a top view of a solar power generation system according to an exemplary embodiment of the present invention;

[0027] Figure 2A yes Figure 1 A partially separated perspective view of an exemplary embodiment of a solar module mounting bracket assembly for a solar power generation system;

[0028] Figure 2B is a top perspective view of an alternative embodiment of a coupling device for coupling a solar module to a rail;

[0029] Figure 2C yes Figure 2B A bottom perspective view of a coupling device;

[0030] Figure 3 Is displayed in the expanded or in-use configuration Figure 2A an enlarged side view of a mounting bracket assembly;

[0031] Figure 4 is shown in folded or transport configuration Figure 2A an enlarged side view of a mounting bracket assembly;

[0032] Figure 5 is shown in the expanded configuration Figure 2A a partially separated side view of a mounting bracket assembly;

[0033] Figure 5A is a top perspective view of an alternative embodiment of a coupling nut illustrated in an attached state and a detached state;

[0034] Figure 6 is shown in a collapsed configuration Figure 2A a side view of a mounting bracket assembly;

[0035] Fig. 7A yes Figure 5 an enlarged view of the detail area designated as "7A" in Figure 1 illustrating the fastener assembly disposed in an inward position relative to the rail of the mounting bracket assembly;

[0036] Figure 7B It is along Fig. 7A A cross-section of a fastener assembly coupled to a rail of a mounting bracket assembly taken along line “7B”;

[0037] Fig. 8A yes Figure 6 an enlarged view of the detail area designated as "8A" in Figure 1 illustrating the fastener assembly disposed in an outward position relative to the rail of the mounting bracket assembly;

[0038] Figure 8B It is along Fig. 8A A cross-section of a fastener assembly coupled to a rail of a mounting bracket assembly taken along line “8B”;

[0039] Fig.9A is shown in a folded configuration and supported on Figure 1 A top perspective view of a mounting bracket assembly on a torque tube of a solar power generation system;

[0040] Fig. 9B is shown in an expanded configuration and supported on Figure 1 A top perspective view of a mounting bracket assembly on a torque tube of a solar power generation system;

[0041] Fig. 9C is an enlarged side view of the mounting bracket assembly shown secured to the torque tube;

[0042] Fig.9D is a bottom perspective view of a mounting bracket assembly attached to the underside of an alternative embodiment of a solar module having a wire management clip;

[0043] Fig.9E It is shown as a phantom Fig.9D A top perspective view of a solar module of FIG. 1 , thereby revealing the wire management clip; and

[0044] Fig.10 is a side cross-sectional view of an alternative embodiment of a rail of a mounting bracket assembly. DETAILED DESCRIPTION

[0045] Embodiments of the presently disclosed solar module mounting bracket assembly and methods of mounting the same are described in detail with reference to the accompanying drawings, in which like reference numerals designate like or corresponding elements in each of the several views. As described herein, the term "solar module" refers to any suitable solar panel or solar panel array that converts energy from the sun into usable energy.

[0046] According to various example embodiments of the present invention, the present invention is directed to a mounting bracket assembly for coupling one or more solar modules (e.g., PV modules) to a frame. The mounting bracket assembly has a rail for attaching one or more PV modules thereto, and a pair of supports pivotably coupled to the rail. The supports are movable from a folded configuration to an unfolded configuration relative to the rail. The folded configuration reduces the overall footprint of the mounting bracket assembly, thereby reducing packaging and shipping costs. In the unfolded configuration, the supports grasp a frame (e.g., a torque tube) to secure the mounting bracket assembly and then the one or more PV modules to the frame. The mounting bracket assembly may also include a pair of truss arms coupled to respective supports to provide support for the supports. The truss arms are configured to fold together with the supports. These and further details of the mounting bracket assembly will be described below.

[0047] refer to Figure 1, a solar power generation system 10 is illustrated and generally includes an array of solar modules 12 (e.g., PV modules), a frame (e.g., a torque tube 14, for example), and mounting bracket assemblies 100 for coupling the array of PV modules 12 to the torque tube 14. Each of the mounting bracket assemblies 100 may be vertically oriented relative to the torque tube 14 and extend laterally below each of the PV modules 12. The torque tube 14 may be rotated about an axis to adjust the angular orientation of the PV modules 12 relative to the sun.

[0048] Although not illustrated, the system 10 may include more than one torque tube 14 connected end-to-end and wherein each set of end-to-end connected torque tubes 14 is arranged as parallel to each other. Each torque tube 14 may have an array of PV modules 12 attached thereto via a plurality of mounting bracket assemblies 100. In an embodiment, two mounting bracket assemblies 100 may be used to couple four PV modules 12 to a torque tube 14. It is contemplated that any suitable number of mounting bracket assemblies 100 may be employed to attach any suitable number of PV modules 12 to a torque tube 14.

[0049] refer to Figures 2A to 9C , an exemplary mounting bracket assembly 100 is illustrated and generally includes an elongated rail 102, a pair of first and second supports 104, 106 movably coupled to the rail 102, and a pair of first and second truss arms 108, 110 for supporting the first and second supports 104, 106 relative to the rail 102. The rail 102 has a generally rectangular shape and a U-shaped cross-sectional configuration. The rail 102 includes an upper wall 112 and a pair of lateral side walls 114, 116 extending vertically downward from the upper wall 112, thereby forming a U-shaped channel 118 in the underside of the rail 102. The rail 102 has opposing first and second ends 102a, 102b and defines a longitudinal axis "X" therebetween. It is contemplated that the rail 102 may be of any suitable shape, such as square, circular, or the like.

[0050] Specific reference Figure 2A, the rail 102 has a plurality of coupling devices 120 disposed on an upper wall 112 of the rail 102. The coupling devices 120 are spaced apart from one another along a longitudinal axis "X" of the rail 102. Each of the coupling devices 120 includes a support member 122 secured to the upper wall 112 of the rail 102 and a clip 124 removably coupled to the support member 122. The support member 122 may be made of a relatively flexible material (e.g., for example, an elastomer) to provide a more forgiving surface on which the PV module 12 will sit. The support member 122 defines an opening 126 therethrough that is sized to receive a shield 128. The shield 128 extends upward from the upper wall 112 of the rail 102 and is secured thereto. The clip 124 of the coupling device 120 includes a plate member 130 and a fastener 132 (e.g., a screw) extending downward from the plate member 130. The fastener 132 of the clip 124 is configured to couple with the shroud 128 (eg, via a threaded engagement or a friction fit engagement).

[0051] Figure 2B A further aspect of the invention is depicted in relation to the coupling device 120. Specifically, this aspect employs a pad 125 that supports the support member 122 and is received on a shroud 128 to attach the pad 125 to the rail 102. In an embodiment, the pad 125 may have a plurality of lugs 127 configured to clip the pad 125 to the upper wall 112 of the rail 102. It is contemplated that the pad 125 may have any suitable fastening mechanism for attachment to the rail 102, such as, for example, an adhesive. The pad 125 allows the width of the rail 102 to be reduced while providing sufficient bearing surface for the solar module 12. The pad 125 may be formed of sheet metal and placed below the support member 122. The increased width of the pad 125, compared to the width of the rail 102, allows the rail 102 to provide increased support for the module 12 while limiting the size of the rail 102 and thus reducing weight and potential cost. Figure 2C Depicted is a bottom perspective view of the coupling device 120 attached to the rail 102 and showing the pad 125 and support member 122 extending over the edge of the rail 102 .

[0052] During assembly, between a pair of adjacent PV modules 12 ( Figure 1 ) is positioned on the support member 122 of the coupling device 120, the fastener 132 of the clip 124 is positioned through the opening 126 of the support member 122 and threadedly coupled to the threaded inner surface of the shield 128. In an embodiment, the fastener 132 of the clip 124 can be fastened to the shield 128 via a friction fit engagement. The plate member 130 of the clip 124 is approached toward the support member 122 (e.g., via rotation of the fastener 132) until the PV module 12 is captured between the plate member 130 of the clip 124 and the support member 122.

[0053] It is contemplated that the rail 102 may also have a coupling device in the form of a flexible, hook-shaped member 134 disposed on the opposing first and second ends 102a, 102b of the rail 102. The hook-shaped member 134 is configured to snap over the end of the PV module 12 to resist movement of the PV module 12 along the longitudinal axis "X" of the rail 102.

[0054] The first end 102a of the rail 102 defines a first pair of linear tracks 136 ( Figure 2A Similarly, the second end 102b of the rail 102 defines a second pair of linear tracks 138 ( Figure 2A Only the track 138 in the first side wall 114 is illustrated. In embodiments, the tracks 136, 138 may be curved or in any other suitable shape. As will be described in further detail below, the first pair of tracks 136 allows for slidable coupling of the first truss arm 108 to the rail 102, and the second pair of tracks 138 allows for slidable coupling of the second truss arm 110 to the rail 102.

[0055] like Figure 3 and 4 As best shown, the rail 102 has a center portion 102c disposed between the first and second ends 102a, 102b of the rail 102. The center portion 102c of the rail 102 may have an insert 140 disposed within the channel 118 of the rail 102 and between the pair of supports 104, 106. The insert 140 has a concave inner surface 142 and a protrusion 144 extending downwardly from its inner surface 142. The protrusion 144 may have a circular configuration (e.g., a dome shape) and be made of a pliable material (e.g., for example, an elastomer). In some embodiments, the protrusion 144 may be made of any suitable material (e.g., for example, a metal). The protrusion 144 is configured to enhance the connection between the mounting bracket assembly 100 and the torque tube (104, 106) when the torque tube 14 is captured between the pair of supports 104, 106. Figure 1 ) between friction engagement as will be described.

[0056] refer to Figures 2A to 6 , each of the first and second supports 104, 106 has a first end 104a, 106a and a second end 104b, 106b. The first end 104a, 106a of each of the supports 104, 106 is coupled to the central portion 102c of the rail via a fastener (e.g., for example, a nut and bolt assembly). The first ends 104a, 106a of the supports 104, 106 may be positioned relative to the rail 102 in a use or deployed configuration (e.g., Figure 3 transport or folded configuration (as shown) Figure 4 In the deployed configuration, the supports 104, 106 are disposed in a perpendicular relationship to the longitudinal axis "X" of the rail 102. In the folded configuration, the supports 104, 106 are coaxial with the longitudinal axis "X" of the rail 102, whereby the mounting bracket assembly 100 has a significantly reduced overall profile.

[0057] Each of the supports 104, 106 may have a concave inner surface 146, 148, respectively. When the supports 104, 106 are in the deployed configuration, the concave inner surfaces 146 of the supports 104, 106 and the concave inner surface 142 of the insert 140 cooperatively define a circular channel 150 sized to receive the torque tube 14 ( Figure 1 ). The supports 104, 106 each have a generally U-shaped cross-sectional configuration and define longitudinally extending U-shaped channels 152, 154, respectively. The U-shaped channels 152, 154 of each of the supports 104, 106 are configured to receive the lateral sidewalls 114, 116 of the rail 102 when the supports 104, 106 are moved toward the folded configuration.

[0058] The mounting bracket assembly 100 further includes a primary fastener 156, such as, for example, a nut 156a and a bolt 156b, which interconnects the second portions 104b, 106b of the first and second supports 104, 106. The primary fastener 156 is configured to extend through openings 158, 160 ( Figure 4 The primary fastener 156 is configured to selectively lock the supports 104, 106 in the deployed configuration and close the circular passage 150. Approaching of the nut 156a and bolt 156b drives the second ends 104b, 106b of the supports 104, 106 closer to each other to shrink the circular passage 150 around the torque tube 14.

[0059] Figure 5A1 and 1 . A nut 157 that may be used with the present invention is depicted in FIG. Specifically, nut 157 is a breakaway shear nut and may be used in place of nut 156a. Breakaway shear nut 157 may be pre-installed on bolt 156b. To install to the proper torque setting, all the installer must do is apply torque to nut 157 until hex head 157a separates from body 157b. The stress concentration of breakaway shear nut 157 may be sized so that separation of hex head 157a occurs when a predetermined pressure is applied to bolt 156b that will hold mounting bracket assembly 100 to torque tube 14. Hex head 157a may then be discarded, but importantly, for field installation, proper torque application may be ensured without requiring any special tools or concern for over-torqueing of nut 157 that may cause damage to torque tube 14 or other components.

[0060] Continue to refer Figures 2A to 6 As briefly mentioned above, the mounting bracket assembly 100 further includes a pair of first and second truss arms 108, 110 that provide support for the supports 104, 106 when in the deployed configuration. Each of the truss arms 108, 110 has a first end 108a, 110a and a second end 108b, 110b. The first end 108a, 110a of each of the truss arms 108, 110 is coupled to the respective second end 104b, 106b of the supports 104, 106 via a fastener, such as, for example, a nut and bolt assembly. The first end 108a, 110a of each of the truss arms 108, 110 may be disposed within a U-shaped channel 152, 154 of the respective supports 104, 106.

[0061] The first end 108a, 110a of each of the truss arms 108, 110 may be positioned relative to the respective support member 104, 106 in an in-use or deployed configuration (eg, Figure 3 transport or folded configuration (as shown) Figure 4 In the deployed configuration, the truss arms 108, 110 are disposed in an oblique or transverse relationship to the longitudinal axis "X" of the rails 102 and supports 104, 106, thereby imparting a generally triangular or A-shape to the mounting bracket assembly 100. In the folded configuration, the truss arms 108, 110 are disposed in a parallel relationship to the rails 102 and supports 104, 106, thereby imparting a substantially linear configuration to the mounting bracket assembly 100.

[0062] refer to Figure 2A , 56, the second end 108b, 110b of each of the truss arms 108, 110 is slidably coupled to the respective first and second ends 102a, 102b of the rail 102. In particular, the second end 108b, 110b of each of the truss arms 108, 110 is configured to slide along the respective tracks 136, 138 of the rail 102 in an inward position ( Figure 5 ) and outward position ( Figure 6 When the second end 108b, 110b of each of the truss arms 108, 110 is in the inward position, the truss arms 108, 110 and the supports 104, 106 are in their respective deployed configurations, and when the second end 108b, 110b of each of the truss arms 108, 110 is in the outward position, the truss arms 108, 110 and the supports 104, 106 are in their respective folded configurations.

[0063] refer to Figures 5 to 8B , the mounting bracket assembly 100 further includes a pair of first and second fastener assemblies 170, 172. The first fastener assembly 170 slidably couples the second end 108b of the first truss arm 108 to the track 136 of the first end 102a of the rail 102, and the second fastener assembly 172 slidably couples the second end 110b of the second truss arm 110 to the track 138 of the second end 102b of the rail 102. The fastener assemblies 170, 172 are configured to selectively lock the second end 108b, 110b of each of the respective truss arms 108, 110 in an inward position. Since the first and second fastener assemblies 170, 172 are the same or substantially similar, only the first fastener assembly 170 will be described in detail herein.

[0064] Specific reference Figures 7A to 8B , the first fastener assembly 170 includes a pair of washers 174, 176 and a fastener 178, such as, for example, a nut and bolt that couple the pair of washers 174, 176 to each other. The washers 174, 176 are disposed on the respective first and second lateral side walls 114, 116 of the rail 102, and the fastener 178 extends laterally through the pair of tracks 136 in the first and second lateral side walls 114, 116 of the first end 102a of the rail 102. The fastener 178 also extends through the second end 108b of the first truss arm 108, thereby slidably coupling the second end 108b of the truss arm 108 to the first end 102a of the rail 102.

[0065] Each of the washers 174, 176 of the fastener assembly 170 includes a pair of first and second flanges or lugs 174a, 174b and 176a, 176b extending vertically from its periphery. The first and second lugs 174a, 174b and 176a, 176b of each of the washers 174, 176 are disposed on opposite sides of the respective washers 174, 176. The lugs 174a, 174b and 176a, 176b of the washers 174, 176 may have a square configuration and be sized to be received in a pair of corresponding grooves 180, 180b defined in the first end 102a of the rail 102 ( Fig. 8A ). The grooves 180a, 180b are disposed on opposite longitudinal sides of the track 136 and at the inward end of the track 136.

[0066] like Fig. 7A As shown, when the fastener assembly 170 is moved toward the inward position, the lugs 174a, 174b and 176a, 176b of the washers 174, 176 align with the corresponding slots 180a, 180b in the first end 102a of the rail 102. Actuation of the fastener 178 drives the approximation of the washers 174, 176, whereby the lugs 174a, 174b of the washers 174, 176 are received in the corresponding slots 180a, 180b in the rail 102 to secure or lock the fastener assembly 170 to the rail 102, and then lock the second end 108b of the first truss arm 108 in the inward position.

[0067] The washers 174, 176 may further include a third flange or lug 174c extending vertically from the periphery thereof. The third lug 174c is received in the track 136 of the first end 102a of the rail 102 to guide the fastener assembly 170 along the track 136. A compression tube 179 ( Figure 7B ), the compression tube 179 extends between the walls 114, 116 of the rail 102 and has a fastener 178 extending therethrough. The compression tube 179 prevents the walls 114, 116 of the rail 102 from folding during the tightening of the fastener 178.

[0068] about Figure 7B and 8B1, illustrates aspects of the present invention relating to capturing the compression tube 179 in the truss arm 108. Specifically, after a hole is formed in the truss arm 108 for receiving the fastener 178, the compression tube 179 can be placed opposite the hole, and a hydraulic press can be used to flare the edges of the hole into the compression tube 179, thereby pressing the edges defining the hole around and onto the inner periphery of the compression tube 179. The result is twofold. First, the flared hole is larger than the hole originally drilled in the truss arm 108, thereby allowing the passage of a fastener 178 having a larger diameter than the hole originally formed. The second result is that the compression tube 179 is permanently captured in the truss arm 108, thereby facilitating installation in the field because the installer no longer needs to align the drilled hole of the compression tube 179 with the hole in the truss arm 108.

[0069] During assembly, refer to Fig.9A When in the folded or transport configuration, the mounting bracket assembly 100 is positioned on the solar power generation system 1 ( Figure 1 ) above the torque tube 14, wherein the central portion 102c of the rail 102 overlaps the torque tube 14. In this position, the protrusion 144 ( Figure 3 ) are adjacent to the outer surface of the torque tube 14, and the supports 104, 106 are disposed on opposite sides of the torque tube 14. Fig. 9B As shown, the support members 104, 106 of the mounting bracket assembly 100 are arranged along Fig. 9B 106. The support members 104, 106 rotate outwardly from the rails 102 toward the deployed configuration in the direction indicated by arrow "A". The rotation of the supports 104, 106 causes the first ends 108a, 110a of each of the truss arms 108, 110 to rotate relative to the respective second ends 104b, 106b of the supports 104, 106. The rotation of the supports 104, 106 continues until the inner surfaces 146, 148 of the supports 104, 106 capture the torque tube 14 therebetween, as shown in FIG. Fig. 9C shown.

[0070] When the torque tube 14 is captured within the channel 150 defined by the insert 140 and the supports 104, 106, the primary fastener 156 is actuated to approach the second ends 104b, 106b of the supports 104, 106, whereby the supports 104, 106 apply an upwardly directed force to the torque tube 14 to drive the torque tube 14 into engagement with the protrusion 144 of the insert 140. In an embodiment, the concave inner surfaces 146, 148 of the supports 104, 106 may be coated or lined with a material similar to the protrusion 144 to enhance frictional engagement with the torque tube 14.

[0071] As described above, when the supports 104, 106 are brought into the deployed configuration, the second ends 108b, 110b of each of the truss arms 108, 110 are simultaneously moved to an inward position on the respective tracks 136, 138 of the rail 102. With the second ends 108b, 110b of the truss arms 108, 110 in the inward position, the first and second lugs 174a, 174b and 176a, 176b of the washers 174, 176 of the fastener assembly 170 are disposed adjacent to the slots 180a, 180b defined in the rail 102. In order to secure the second ends 108b, 110b of the truss arms 108, 110 in the inward position along the respective tracks 136, 138, the fasteners 178 of the fastener assembly 170 are actuated to drive the approximation of the washers 174, 176, whereby the lugs 174a, 174b and 176a, 176b of the washers 174, 176 are received in the corresponding slots 180a, 180b in the rail 102 to secure or lock the fastener assembly 170 to the rail 102, and then lock the second end 108b of the first truss arm 108 in the inward position.

[0072] At this stage, the remaining fasteners of the mounting bracket assembly 100 may be tightened to ensure that the mounting bracket assembly 100 remains secured in the deployed or in-use configuration. Next, the PV module 12 is secured to the rail 102 of the mounting bracket assembly 100 via the coupling devices 120, 134 in the manner described above.

[0073] exist Fig.9D and 9E Still further aspects of the present invention can be seen in . Specifically, the rail 102 can have pre-installed wire management clips 162 attached to the lateral sides of the rail 102. The wire management clips 162 can be axially aligned with each other and spaced apart along the rail 102. In other embodiments, the clips 162 can be positioned at any suitable location on the rail 102 or other components of the mounting bracket assembly 100. With the pre-installed wire management clips 162, the installation of the solar modules 12 and their electrical connections are facilitated, and both are made more efficient and ensure the quality of those electrical connections by having pre-installed wire management clips 162 available to the installer.

[0074] Finally, although generally described in conjunction with rails 102 having a generally C-shaped cross-section, the present invention is not limited thereto. Rather, a variety of cross-sectional shapes may be employed without departing from the scope of the present invention. For example, a rail 102 having a generally C-shaped cross-section may be employed. Fig.10 Top-hat configuration depicted. Top-hat rail 102 is similar to a C-rail, but includes two flanges 107a, 107b extending perpendicularly from the channel, which provide further stability to rail 102. In various aspects, flanges 107a, 107b may extend at any suitable angle relative to the body of the rail.

[0075] In embodiments, the fasteners described herein may be any suitable fastening mechanisms including, but not limited to, adhesives, hinges, clips, ties, straps, belts, tapes, and / or fabric hook and loop fasteners.

[0076] It should be understood that various modifications may be made to the embodiments disclosed herein. Therefore, the above description should not be interpreted as limiting, but only as an illustration of various embodiments. Those skilled in the art will envision other modifications within the scope and spirit of the appended claims.

Claims

1. A mounting bracket assembly, comprising: a rail having a longitudinal axis; a pair of supports each having a first end movably coupled to the rail, wherein the pair of supports are movable relative to the rail between a folded configuration and an expanded configuration, wherein in the expanded configuration the pair of supports cooperatively define a channel sized to receive a frame member; and A pair of truss arms comprising: a first end portion movably coupled to a corresponding second end portion of the pair of supports; and A second end portion is movably coupled to the respective first and second ends of the rail. 2 . The mounting bracket assembly of claim 1 , wherein the pair of supports are parallel to the rail in the folded configuration and perpendicular to the rail in the deployed configuration.

3. The mounting bracket assembly of claim 1 , wherein when the pair of supports are in the folded configuration, the mounting bracket assembly is substantially linear in shape, and wherein when the pair of supports are in the unfolded configuration, the mounting bracket assembly is substantially triangular in shape. 4 . The mounting bracket assembly of claim 1 , further comprising a fastener configured to attach to the second end of each of the pair of supports to secure the pair of supports in the deployed configuration.

5. The mounting bracket assembly of claim 1 , wherein the pair of truss arms are configured to move between a folded configuration and an unfolded configuration relative to the rail and the pair of supports, wherein in the folded configuration the pair of truss arms are parallel to the rail and the pair of supports, and in the unfolded configuration the pair of truss arms extend perpendicularly relative to the rail.

6. The mounting bracket assembly of claim 5, wherein the second end of each of the pair of truss arms is configured to slide away from a center portion of the rail when the pair of truss arms are moved toward the folded configuration.

7. The mounting bracket assembly of claim 5, wherein the second end of each of the pair of truss arms moves along the rail from an inward position toward an outward position, wherein in the inward position the pair of truss arms are in the deployed configuration and in the outward position the pair of truss arms are in the folded configuration.

8. The mounting bracket assembly of claim 5, wherein each of the first and second ends of the rail defines a track through which the respective second ends of the pair of truss arms slide.

9. The mounting bracket assembly of claim 8, further comprising a fastener assembly coupled to the second end of the first truss arm of the pair of truss arms, wherein the fastener assembly is configured to selectively secure the second end of the first truss arm in position on the track of the rail.

10. The solar module mounting bracket assembly of claim 9, wherein the fastener assembly comprises: a pair of washers disposed on opposite sides of the rail, at least a first washer of the pair of washers having a pair of first and second lugs extending therefrom, the pair of first and second lugs being configured to be received in corresponding slots defined in the rail; and A fastener couples the pair of washers to each other and is configured to adjust a distance between the pair of washers.

11. The mounting bracket assembly of claim 10, wherein the first washer of the fastener assembly further includes a third lug extending therefrom, the third lug disposed in the track of the rail to guide the fastener assembly through the track.

12. The mounting bracket assembly of claim 1, further comprising a protrusion projecting downwardly relative to a bottom side of the rail, wherein the protrusion extends into the channel defined by the pair of supports when the pair of supports are in the deployed configuration.

13. The mounting bracket assembly of claim 1, wherein each of the pair of supports has a concave inner surface such that the channel cooperatively defined by the first and second supports has a circular shape.

14. The mounting bracket assembly of claim 1, further comprising a plurality of coupling devices disposed on an upper side of the rail, wherein the plurality of coupling devices are configured to secure a solar module to the rail.

15. A solar module mounting bracket assembly, comprising: a rail having a longitudinal axis; and A pair of supports, each having a first end movably coupled to the rail, wherein the pair of supports are movable relative to the rail between a folded configuration and an expanded configuration, wherein in the folded configuration the pair of supports are parallel to the rail and in the expanded configuration the pair of supports are perpendicular to the rail, wherein the pair of supports cooperatively define a channel sized to receive a frame member, wherein each of the pair of supports has a concave inner surface such that the channel cooperatively defined by the first and second supports has a circular shape.

Images