Support structure and mounting system for solar panels

Abstract

A solar panel support structure includes: a first shelf for supporting a first frame portion of a first solar panel module, the first shelf defining a first plane; and a second shelf for supporting a second frame portion of a second solar panel module, the second shelf defining a second plane. A partition structure is disposed between the first shelf and the second shelf and extends over the first plane and the second plane. The first shelf turn-up may be disposed at an end of the first shelf distal from the partition structure and extend over the first plane. A second shelf turn-up may be disposed at an end of the second shelf remote from the partition structure and extend over a second plane. The support structure includes one or more movable first locking tabs for engaging the first bottom flange portion and the second bottom flange portion of the frame portion.

Description

Technical Field

[0001] The present disclosure is directed to various embodiments of support structures and mounting systems for panels, such as solar panels. Background Art

[0002] Photovoltaic solar panels for residential and commercial use are relatively large and bulky. For example, a typical rectangular solar panel can weigh about 20-30 kg, with a width of about 1 meter, a length of about 1.6-2.5 meters, and a thickness of about 3-5 centimeters. Photovoltaic solar panels can generally be multi-layer laminated structures (sometimes referred to as PV laminates), and can include photovoltaic cells encapsulated between top glass and a protective backplane. The solar panel can further include appropriate wiring and junctions so that the electricity (usually DC) generated by the sun can be transmitted to a desired load, power grid, or energy storage unit. Although the panel has some physical toughness, significant additional strength can be provided by including the panel in a frame. The frame can allow the photovoltaic solar panel to be easily attached to the bracket. PV laminates with frames are sometimes referred to as PV modules.

[0003] Over the years, the cost of solar panels may have decreased due to reductions in material and manufacturing costs and even increases in the efficiency of solar cells. However, in order to further expand the use of renewable solar energy, there is a constant desire to further reduce costs and simplify the manufacture of the framework. Summary of the invention

[0004] The present application includes multiple aspects, which can be selected in different combinations based on a specific application or a need to be solved. In various embodiments, the application can include a solar panel support structure, the solar panel support structure including: a first shelf for supporting a first frame portion of a first solar panel module, the first shelf defining a first plane; and a second shelf for supporting a second frame portion of a second solar panel module, the second shelf defining a second plane. A partition structure is disposed between the first shelf and the second shelf and extends above the first plane and the second plane. The first shelf upper flip portion can be disposed at an end of the first shelf away from the partition structure and extending above the first plane. The second shelf upper flip portion can be disposed at an end of the second shelf away from the partition structure and extending above the second plane. The support structure includes one or more first movable locking tabs, the one or more first movable locking tabs being disposed at the following positions: i) the partition structure; ii) the first shelf upper flip portion; or both (i) and (ii) for engaging a first bottom flange portion of the first frame portion. The support structure also includes one or more second movable locking tabs, which are arranged at the following positions: i) the partition structure; ii) the second shelf upper flip portion; or both (i) and (ii) for engaging the second bottom flange portion of the second frame portion.

[0005] Some embodiments of the present application may provide a support structure and mounting system having one or more of the following advantages: improved strength; improved bending; improved torsion; improved durability; reduced material cost; reduced manufacturing cost; reduced assembly cost; higher manufacturing yield; reduced manufacturing tight time; reduced installation cost; simplified installation; reduced installation time; higher installation yield; or some other advantage.

[0006] Of course, other objects, goals and embodiments of the present application are disclosed throughout the specification, claims and other parts of the drawings. BRIEF DESCRIPTION OF THE DRAWINGS

[0007] Figure 1A is a plan view of a non-limiting example of a framed panel structure according to some embodiments.

[0008] Figure 1B According to some embodiments, Figure 1A A cross-sectional view of a non-limiting example of a framed panel structure taken along section line BB.

[0009] Figure 1C is a non-limiting example showing only a framework according to some embodiments. Figure 1B sectional view of .

[0010] Figure 2Ais a plan view of a non-limiting example of a frame precursor structure and panels prior to assembly of a framed panel structure according to some embodiments.

[0011] Figure 2B According to some embodiments, Figure 2A A cross-sectional view of a non-limiting example of a frame front structure and a panel taken along section line BB.

[0012] Figure 2C yes Figure 2B , showing a non-limiting example of a framework precursor structure only, according to some embodiments.

[0013] Figure 2D is an elevated side view of a non-limiting example of a framework precursor structure according to some embodiments.

[0014] Figure 2E is a plan view of a non-limiting example of a frame precursor structure and panels at an intermediate stage of assembly according to some embodiments.

[0015] Figure 3 is a plan view illustrating a non-limiting example of assembling a frame using four frame precursor structures according to some embodiments.

[0016] Figure 4A is a perspective view of a non-limiting example of a frame including a crossbar, according to some embodiments.

[0017] Figure 4B According to some embodiments Figure 4A Magnified view of area B.

[0018] Figure 5 is a schematic diagram of a non-limiting example of a manufacturing line for manufacturing a framework precursor structure according to some embodiments.

[0019] Fig. 6A is a perspective view of a cut-away portion of a non-limiting example of a frame portion including a support wall according to some embodiments.

[0020] Figure 6B According to some embodiments Fig. 6A A cross-sectional view of a frame portion.

[0021] Figure 6C is a plan view of a non-limiting example of a portion of a frame material according to some embodiments.

[0022] FIG. 6D to FIG. 6F is a cross-sectional view of a non-limiting example of a framed panel structure according to some embodiments.

[0023] Fig. 7Ais a cross-sectional view of a non-limiting example of a solar panel mounting system according to some embodiments.

[0024] Figure 7B is a cross-sectional view of a frame portion according to some embodiments.

[0025] Figure 7C and Fig.7D is a perspective view of a support structure according to some embodiments.

[0026] Fig. 8A is a cross-sectional view of a non-limiting example of a solar panel mounting system according to some embodiments.

[0027] Figure 8B is a cross-sectional view of a non-limiting example of a support structure according to some embodiments.

[0028] Figure 8C is a perspective view of a non-limiting example of a support structure according to some embodiments.

[0029] Figure 9A-9D is a cross-sectional view of various elements of a non-limiting example of a solar panel mounting system using a wedge, according to some embodiments.

[0030] Figures 10A-10J are various views of various elements of another non-limiting example of a solar panel mounting system using a wedge, according to some embodiments.

[0031] Fig.11A is a cross-sectional view of a non-limiting example of a solar panel mounting system according to some embodiments.

[0032] Fig. 11B is a cross-sectional view of a non-limiting example of a support structure according to some embodiments.

[0033] Fig. 11C is a perspective view of a non-limiting example of a support structure according to some embodiments.

[0034] Fig.11D is a perspective view of a non-limiting example of a solar panel mounting system according to some embodiments.

[0035] Fig. 12A is a perspective view of a non-limiting example of a solar panel mounting system using attachment clips according to some embodiments.

[0036] Fig. 12B is a cross-sectional view of a non-limiting example of a support structure according to some embodiments.

[0037] Fig. 12C and Fig.12Dare perspective and cross-sectional views, respectively, of non-limiting examples of attachment clips according to some embodiments.

[0038] Fig.12E and Fig.12F are cross-sectional and perspective views of non-limiting examples of frame portions according to some embodiments.

[0039] Figure 12G is a cross-sectional view of a non-limiting example of a solar panel mounting system using attachment clips according to some embodiments.

[0040] Fig.12H yes Figure 12G An enlarged cross-sectional view of a non-limiting example of a solar panel mounting system.

[0041] Fig.12I is a cross-sectional view of a non-limiting example of an attachment clip according to some embodiments.

[0042] Fig.12J is a cross-sectional view of a non-limiting example of a solar panel mounting system using attachment clips according to some embodiments.

[0043] Figure 12K yes Fig.12J An enlarged cross-sectional view of a non-limiting example of a solar panel mounting system.

[0044] Figure 12L is a cross-sectional view of a non-limiting example of an attachment clip according to some embodiments. DETAILED DESCRIPTION

[0045] It should be understood that the embodiments include multiple aspects that can be combined in different ways. The following description is provided to list the elements and describe some of the embodiments of the present application. These elements are listed together with the initial embodiment; however, it should be understood that these elements can be combined in any way and in any number to produce additional embodiments. The various described examples and embodiments should not be interpreted as limiting the embodiments of the present application to only the systems, technologies and applications that are clearly described. The one or more specific embodiments shown are only examples. This specification should be understood and intended to support broad claims and each embodiment, and even claims that exclude other embodiments. Importantly, only disclosing exemplary embodiments does not mean limiting the width of other more inclusive claims that can be made in such a case, and the claims can be only one of several methods or embodiments that can be used in broader claims, etc. In addition, this specification should be understood to support and include descriptions and claims of all various embodiments, systems, technologies, methods, devices and applications, all of which have any number of disclosed elements, each of which is used alone, and also have any permutations and combinations of all elements in this application or any subsequent application and all various permutations and combinations.

[0046] It should be understood that the drawings are for the purpose of illustrating the concepts of the present disclosure and may not be drawn to scale. Other details of certain embodiments of the present application can be found in the following applications: PCT application No. PCT / US2020 / 037092, filed on June 10, 2020, published as WO2020 / 252091A1; PCT application No. PCT / US2022 / 025383, filed on April 19, 2022; PCT application No. PCT / US2022 / 025388, filed on April 19, 2022; and PCT application No. PCT / US2022 / 029668, filed on May 17, 2022, the entire contents of which are incorporated herein by reference for all purposes.

[0047] Figure 1A is a plan view of a non-limiting example of a framed panel structure 100 (e.g., a framed solar panel structure, a solar panel module, or a PV module) according to some embodiments, wherein the framed panel structure 100 includes a panel 190 (e.g., a solar panel) encapsulated in a frame 101 or otherwise supported by the frame 101. Figure 1B is a cross-sectional view of the framed panel structure 100 taken along section line BB. For additional perspective, the XYZ coordinate axes are also shown. Figure 1C is with Figure 1B1, but without the panels, further illustrating some of the features of frame 101.

[0048] In some embodiments, as discussed in more detail herein, the frame 101 can be formed of a substantially single frame precursor structure that can be bent in a predetermined area to accommodate three corners of a solar panel, or a fourth corner forming a joint between two ends of the frame precursor structure. That is, in some cases, the frame 101 can include: a first corner bend 112 corresponding to a first corner of the panel 190; a second corner bend 114 corresponding to a second corner of the panel 190; a third corner bend 116 corresponding to a third corner of the panel 190; and even a corner joint 118 corresponding to a fourth corner of the panel 190.

[0049] Reference Figure 1B and Figure 1C , frame 101 may include frame material that has been cut and folded into a desired shape. Frame 101 may be characterized by a height H and may include a longitudinal fold 102 that defines the intersection of frame sidewalls 103 and bottom flanges 104. The frame may further include a series of folds to form a panel containment structure 191, which includes a lower shelf 105, an optional pocket wall 106, an optional top lip 107, and may even include a pocket area 108. In some embodiments, the bottom flange may generally represent or be disposed at or near the base of the frame ("frame base area") or framed panel structure. In some cases, the bottom flange may be referred to as a frame base. Panel 190 may be housed on the lower shelf, such as in a portion of the pocket area and fixed in place, optionally using a sealant (not shown) that may have adhesive properties. Some non-limiting examples of sealants may include curable liquid silicones, polyurethanes, epoxies, resins, any other liquid seals, etc. Alternatively, or in combination, a pressure-sensitive adhesive tape may optionally be used to secure the panel in the pocket area. In some embodiments, the panel containment structure may include only the lower shelf, or alternatively, only the lower shelf and the pocket wall. In such embodiments, a sealant or pressure-sensitive adhesive as described above may optionally be used to secure the panel in place. Here, the panel containment structure is also referred to as a panel interface structure. In some embodiments, only some of the frame portions may include the panel containment structure, for example, only the frame portions on one set of opposite sides of a rectangular or square panel.

[0050] although Figure 1B and Figure 1CNon-limiting examples are shown in which the bottom flange, lower shelf, and top lip all extend from the frame sidewalls to the same extent, any of these features may vary, such as being shorter or longer than others, etc. The angle between the frame sidewall and the bottom flange is shown as being approximately 90°, such as in the range of approximately 85° to approximately 95°, but in some other embodiments, the angle may be outside of this range, such as in the range of approximately 45° to approximately 135°, possibly depending on other features of the structure and the overall system design. In some embodiments, regardless of the angle between the frame sidewall and the bottom flange, the lower shelf and the bottom flange may remain generally parallel, such as within approximately 40°, alternatively within approximately 30°, approximately 20°, approximately 15°, approximately 10°, or even approximately 5°. The top lip is shown to be parallel to the lower shelf, but in some embodiments, the top lip may be slightly angled or bent at the ends so that the opening of the pocket area may be larger or smaller than the pocket wall. In Figure 1B and Figure 1C In the illustrated embodiment, the lower shelf 105 shown is formed of a frame material, or includes multiple layers of frame material. In some embodiments, any or all of the frame features (e.g., sidewalls, bottom flanges, lower shelf, pocket walls, upper lip, support walls, etc.) can be formed of multiple layers of frame material or include multiple layers of frame material. In some cases, multiple layers can provide increased strength for the frame.

[0051] Figure 1A , Figure 1B and Figure 1C A conventional rectangular panel shape commonly used for solar panels is shown. However, there is no particular limitation on the shape of the panel, which may be any shape, such as a polygon with 3, 4, 5, 6, 7, 8 or more sides. The sides of the polygon may have the same length, or alternatively, some sides may be longer or shorter. The corner angles of the polygon may all be the same, or alternatively, some corner angles may have a smaller or larger angle than other angles. Although the frames and frame portions shown here typically have a bottom flange, in some embodiments, one or more frame portions may not include a bottom flange. In some embodiments where the frame has a rectangular shape, the frame portions corresponding to the shorter sides of the frame may not include a bottom flange, while the frame portions corresponding to the longer sides of the frame may include a bottom flange.

[0052] A frame or frame portion manufactured substantially from a single piece of frame material can have considerable manufacturing, assembly, and cost advantages. However, in some embodiments, the panel containment structure can be formed using alternative methods and materials. For example, the lower shelf can include a sheet of shelf material bonded (e.g., welded, brazed, soldered, glued, riveted, etc.) to the upper portion of the frame sidewall. Similarly, the top lip can include a piece of top lip material bonded to the top of the frame structure. Alternatively, the entire panel containment structure can be a separate structure designed to sit on, slide over, or mate with the frame sidewalls. As discussed elsewhere herein, rather than one long piece of frame material, a 4-sided frame can be formed from 2, 3, or even 4 separate frame portions (or more, or if the frame has more than 4 sides). Although in Figure 1A-Figure 1C , but the frame or framed panel structure may also include a support wall extending from the bottom flange to the panel receiving structure or to the frame side wall, as described in more detail elsewhere herein. It should be noted that throughout this disclosure, the upper lip and top lip may in some cases refer to a general position relative to the bottom flange or base of the frame and do not necessarily indicate a position or orientation in the final framed panel structure, which may be different from the bottom flange or base of the frame. Figure 1B The device may be shown oriented in a horizontal manner (eg, angled on its side, or even partially inverted or completely inverted).

[0053] Figure 2A is a schematic plan view generally illustrating the construction of a framed panel structure according to some embodiments. Figure 2B It is cut along the section line BB Figure 2A sectional view. The frame precursor structure 201 may be formed of a frame material having an average thickness. The frame precursor structure 201 may include a first end 210 and a second end 220 defining a longitudinal dimension. The frame precursor structure 201 may include: a first frame portion 201-1 designed to mate or engage with a first panel edge 190-1 of the panel 190; a second frame portion 201-2 designed to mate or engage with a second panel edge 190-2; a third frame portion 201-3 designed to mate or engage with a third panel edge 190-3; and even a fourth frame portion 201-4 designed to mate or engage with a fourth panel edge 190-4. For example, a lower shelf of a frame portion may engage the bottom surface of a panel at a panel edge region associated with the frame portion. The frame precursor structure 201 may include a first corner bend precursor axis 212 between the first frame portion and the second frame portion, and may be designed to bend along the Z axis (height axis) of the frame sidewall. In the completed framed panel structure, the first corner bend front axis 212 may correspond to the first corner bend 112 ( Figure 1A). Similarly, the frame front body structure 201 may include a second corner bend front body axis 214 and a third corner bend front body axis 216, respectively.

[0054] Reference Figure 2B , cross-sectional structure and Figure 1B The cross-sectional structure of the finished frame is related. Figure 2C Yes Figure 2B , but without the panel, to further illustrate some non-limiting examples of features of the frame precursor structure, particularly the frame portion 201-2. Here, the second frame portion 201-2 may be characterized by a height H and may include a longitudinal fold 202-2 that may define the intersection of the frame side wall 203-2 and the bottom flange 204-2. The second frame portion may include a series of folds to form a panel containment structure 291, which includes a lower shelf 205-2, an optional pocket wall 206-2, an optional top lip 207-2, and may even include a pocket area 208-2. In some embodiments, the bottom flange may generally represent or be set at the base of the frame portion. In some embodiments, the panel containment structure may include only the lower shelf, or, optionally, only the lower shelf and the pocket wall. The panel edge 190-2 of the panel 190 may be contained on the lower shelf, for example, in a portion of the pocket area, and optionally fixed in place with some sealant (not shown). For example, lower shelf 205-2 may engage the bottom surface of the panel at a panel edge region associated with panel edge 190-2. In some embodiments, each frame portion of the frame precursor structure may have a Figure 2B The second frame portion 201-2 in FIG. 1 has substantially the same cross-sectional structure as shown in FIG. However, in some other embodiments, there may be differences in the cross-sectional structure of two or more frame portions. Figure 2B and Figure 2C In the illustrated embodiment, the lower shelf 205-2 is shown as being formed of a frame material or including multiple layers of frame material. In some embodiments, any or all of the frame portion features (e.g., sidewalls, bottom flanges, lower shelf, pocket walls, upper lip, support walls, etc.) may be formed of multiple layers of frame material or include multiple layers of frame material. In some cases, multiple layers may provide increased strength to the frame.

[0055] To accommodate the bend, the frame front structure may include a series of notches (212N, 214N, 216N) in the top lip, lower shelf, or even the bottom flange, corresponding to the first corner bend front axis 212, the second corner bend front axis 214, and the third corner bend front axis 216, respectively. Figure 2AIn the embodiment, the notches are only visible in the top lip (between the top lip 207-1 and the top lip 207-2, between the top lip 207-2 and the top lip 207-3, and between the top lip 207-3 and the top lip 207-4), but similar notches may also exist in the lower shelf and the bottom flange. In some embodiments, the angle of the notch can be about 180° minus the angle of the enclosed panel corner. Similarly, the ends of the frame front structure can also include inclined cuts (210N and 220N) in the top lip, the lower shelf, and the bottom flange to accommodate the formation of the corner joint.

[0056] exist Figure 2D In the figure, a non-limiting example of a schematic side view (with a slight elevation) of a frame front structure facing the side that can accommodate a panel is shown. For clarity, not all features are labeled, but the identification of each feature is obvious in conjunction with the other drawings.

[0057] Reference Figure 2E , a plan view of a non-limiting example of an intermediate state of assembled framed panel structure is shown, wherein frame portion 201-2 of the frame precursor structure has engaged the panel edge region of panel edge 190-2, and a bend is formed along the bend precursor axis as the other frame portions are moved closer to their intended final position around the panel. Note that assembly need not begin at panel edge 190-2, but may begin at any panel edge or corner. The corner joint 118 (see FIG. 1 ) where the two ends (210 and 220) of the frame precursor structure meet is formed. Figure 1A ) may be the last step in this portion of the framed panel structure assembly, but there may be additional steps to further secure or modify the frame (e.g., adding optional support brackets, tightening optional bolts, etc.). In some embodiments, assembling the framed panel structure may include using assembly equipment that holds and manipulates the panels and one or more frame precursor structures. With respect to the orientation of the components relative to the assembly equipment during assembly, Figure 2E The plan views may represent a view from above, or alternatively a view from below, or even a view from the side, depending on the nature of the assembled device.

[0058] In some embodiments, the corner bend and / or corner joint may include features that can form an interlocking structure. For example, a bottom flange or other portion on one side of the corner may include a locking element that can be received on the other side of the corner.

[0059] Despite Figure 2A-2E Not shown, one or more of the frame portions may also include a support wall extending from the bottom flange to the panel receiving structure or to the frame sidewalls, as described in more detail elsewhere herein.

[0060] In some embodiments, the frame precursor structure 201 may be substantially linear (as shown) prior to assembling the framed panel structure. In some embodiments, the frame precursor structure may be received by the assembler which may already be partially bent at one or more corner bend precursor axes. One or more corner bend precursor axes may be pre-scored or include grooves or features that facilitate bending along the height channel between frame portions.

[0061] exist Figure 1A-Figure 1C and Figure 2A-2E The frames and frame precursor structures described in are non-limiting examples provided to illustrate how some of the frame support substructures and frame support walls described below can be implemented in the frame. Alternative designs and structures can be effectively used with such support structures. In some embodiments, instead of using one frame precursor structure, multiple frame precursor structures can be used to enclose the panel. For example, for a rectangular panel, two similar frame precursor structures can be used to form a framed panel structure, each of which has a corner bend precursor axis, and the framed panel structure can include two corner joints at relative corners and two corner bends at relative corners. Alternatively, the first frame precursor structure may have two corner bend precursor axes, and the second frame precursor structure may not have a corner bend precursor axis and is used to form a framed panel structure, which may include two corner joints at adjacent corners and two corner bends at adjacent corners. Alternatively, three frame front structures may be used, one of which may have a corner bend front axis, while the other two may not, whereby the frame panel structure may include one corner bend and three corner joints. Alternatively, four frame front structures may be used, none of which may have a corner bend front axis, and the frame panel structure may include four corner joints.

[0062] Figure 3It is a plan view showing a non-limiting example of assembling a frame using four frame precursor structures according to some embodiments. Each frame precursor structure (wherein each frame precursor structure may also be referred to as a frame portion) 301-1, 301-2, 301-3, 301-4 may optionally include any feature described elsewhere, such as a bottom flange, a side wall, or even a panel accommodating structure, which may include a lower shelf, an optional pocket wall, and an optional top lip. In some cases, one or more frame portions may further include a supporting wall extending from the bottom flange to the panel accommodating structure or to the frame side wall, as described elsewhere herein. In this view, only the top lip 307-1, 307-2, 307-3, 307-4 of each frame precursor structure is visible. Each frame precursor structure may have a first end 310-1, 310-2, 310-3, 310-4 and a second end 320-1, 320-2, 320-3, 320-4. When assembled, a first end of one frame precursor structure may form a corner joint with a second end of an adjacent frame precursor structure. Figure 2E As discussed, Figure 2E The plan views may represent a view from above, or alternatively a view from below, or even a view from the side, depending on the nature of the assembled device.

[0063] As shown by the arrows, the first frame precursor structure can be designed to cooperate with or otherwise engage with the first panel edge 190-1 of the panel 190, the second frame precursor structure 301-2 can be designed to cooperate with or otherwise engage with the second panel edge 190-2, the third frame precursor structure 301-3 can be designed to cooperate with or otherwise engage with the third panel edge 190-3, and even the fourth frame precursor structure 301-4 can be designed to cooperate with or otherwise engage with the fourth panel edge 190-4. There are many variations in the order for assembling the frame. In some embodiments, all four frame precursor structures can be combined with their respective panel edges at the same time and attached at about the same time. In some cases, the attachment can be sequential, and can be any order. In some embodiments, only two or three frame precursor structures are combined with their respective panel edges at the same time, and the remaining frame precursor structures are attached later or have been pre-attached. In some embodiments, two or three of the frame precursor structures can first be attached to each other by a corner joint connection, and then attached to the panel. In some cases, the frame precursor structure may initially be joined together at an angle to its corresponding panel edge rather than being flush or parallel. In some cases, the selection of the assembly sequence may depend in part on the design of the corner joints to be used and the optional corner joint connections. In some embodiments, the corner joint connections may be achieved, for example, using riveting, rivets, screws, nuts / bolts, welding, adhesives, or some other connection methods or mechanisms. Note that welds or welding may refer to any type of weld or welding, including but not limited to gas welding, arc welding, resistance welding, energy beam welding, solid state welding, friction welding, fusion welding, or some other welding.

[0064] In some embodiments, the finished frame (whether made from a continuous piece or from multiple frame sections) may also include one or more crossbars that may extend from one frame section to an opposing or adjacent frame section. In some embodiments regarding a rectangular frame, the crossbar may extend between the two longest opposing frame sections. In some cases, the crossbar may connect two opposing frame sections near their mid-region. The crossbar may serve to strengthen the frame. The crossbar may be connected to the frame at a bottom flange, a frame sidewall, or at some other frame feature including but not limited to a support wall. In some embodiments, the crossbar structure may include an upper surface on which the panels may rest or optionally be adhered. In some cases, the crossbar may be easily attached as part of the panel installation process (e.g., as shown in FIG. 1 ). Figure 2E and Figure 3That is, in some cases, an additional separate step may not be required. In some embodiments, the crossbar can be formed from the frame material used for the rest of the frame. In some embodiments, a different material can be used for the crossbar.

[0065] Figure 4A 4 is a perspective view of a non-limiting example of a frame including a crossbar according to some embodiments. For clarity, the framed panels are not shown. In some cases, the frame 401 may include a first frame portion 401-1, a second frame portion 401-2, a third frame portion 401-3, and even a fourth frame portion 401-4. Crossbar 460 may be connected to the opposing frame portions 401-1 and 401-3. In some embodiments, the connection may be performed, for example, using riveting, crimping, rivets, screws, nuts / bolts, welding, adhesives, or some other connection methods or mechanisms.

[0066] Figure 4B yes Figure 4A 4. In some cases, the first frame portion 401-1 may optionally have a box-shaped frame structure as described below. For example, the frame portion 401-1 may include a bottom flange 404-1, a support wall 432-1, a lower shelf 405-1, a top lip 407-1, and a frame side wall (not visible in this view). In some embodiments, the crossbar 460 may include a crossbar top surface 465 and a crossbar side wall 463. The crossbar 460 may optionally have a box-type structure, which includes another side wall (not visible in this figure) opposite to the crossbar side wall 463 and a bottom flange or bottom surface (not visible in this figure) opposite to the crossbar top surface 465. In some cases, the crossbar top surface 465 may contact the panel and may optionally include an adhesive layer to help fix the panel. In some embodiments, the crossbar top surface 465 may be flush with the lower shelf 405-1 of the first frame portion (e.g., at the same height). In some embodiments, crossbar 465 may be connected to the first frame portion at a frame side wall, a bottom flange, a support wall, or any combination.

[0067] The frame material should have sufficient strength to support the panel. In some embodiments, the frame material may include metals such as uncoated steel, coated steel, stainless steel, aluminum, or another metal or metal alloy (which may be coated or uncoated), etc. In some embodiments, the frame material may be a coated metal including an anti-corrosion coating or treatment, such as coated steel, etc. For example, coated steel may include metallic coated steel, organic coated steel, or tinplate. Some non-limiting examples of metal coatings for steel may include zinc and zinc alloys (e.g., Zn-Al alloys), aluminum, magnesium, etc. Depending on the coating, such metal coatings may be applied by hot-dip galvanizing, electrogalvanizing, thermal spraying, etc. Some non-limiting examples of organic coatings may include polyester or PVDF, which may be applied by paint or other coatable mixtures. Tinplate may be manufactured by applying tin to cold rolled steel, for example, by electroplating. In some embodiments, the thickness of the coated steel used as a frame material can be in the range of about 0.5 to about 0.6 mm, or about 0.6 to about 0.7 mm, or about 0.7 to about 0.8 mm, or about 0.8 to about 0.9 mm, or about 0.9 to about 1.0 mm, or about 1.0 to about 1.2 mm, or about 1.2 to about 1.4 mm, or about 1.4 to about 1.6 mm, or about 1.6 to about 1.8 mm, or about 1.8 to about 2.0 mm, or any combination or permutation of ranges thereof, etc. When the coated steel frame material can be used to make frames for conventional photovoltaic solar panels, in some embodiments, the thickness can be in the range of about 0.7 to about 1.4 mm.

[0068] In some embodiments, the steel can be a steel other than stainless steel. For some applications, such as for photovoltaic solar panels, steel can have a useful combination of technical and commercial benefits. Steel can have properties that can be applied to material selection, manufacturing and long-term durability, which are useful for the form and function of the frame or frame precursor structure product. In the pre-production process, steel can be easily coated with a corrosion-resistant coating that uses a variety of chemical preparations that provide corrosion resistance that can benefit the durability of the frame. Steel can be painted with a clear or specific color that can optionally allow identification of specific module selections of various categories. Because paint or anti-corrosion coatings can be applied in the form of high-speed manufacturing, cost and durability are more effective than most other metals. Steel can be optionally painted and have an anti-corrosion coating, thereby allowing multiple benefits of marking, module identification and long-term maintenance that are superior to non-steel module frames.

[0069] Steel is a highly durable material that can be deformed significantly while maintaining its toughness and resistance to structural damage. The property of toughness when deformed can be referred to as ductility. Due to the ductility of steel, it can be formed from a thin sheet material, such as that wound on a coil, which can be directly fed to a punching station, which can cut or partially cut or create grooves in the surface of the steel sheet using a variety of methods. After the process, the steel that has been improved in the punching station can be fed into a linear and non-linear roller set that can deform the steel panel into a new profile, many of which are possible. Due to the ductility of steel, the process can be carried out at high speeds, with production speeds ranging from less than about 0.1 meters per second to greater than about 4.0 meters per second. The compatibility of steel with such high-speed forming processes can provide significant manufacturing cost advantages. Due to the ductility of steel, it can be bent into simple or complex shapes that will maintain their relative shape or position over the life of the product. In some embodiments, steel that has been formed into simple or complex forms can also be designed to yield or partially yield at specific locations or along a predetermined path as part of the expected installation or operating parameters.

[0070] Steel has electrical properties that allow it to act as an intended electrical code approved path to create an electrical ground or electrical bond. Due to the properties of steel and the corrosion protection or paint coating that may be present, the electrical ground or electrical bonding can still occur without the need for additional hardware or devices. When the steel module frame is directly attached to the steel structure, most electrical codes allow this connection to be considered an effective electrical ground or electrical bonding. This means that the framed panel structure can be directly connected to the steel substructure and it can be considered that the framed panel structure has achieved sufficient electrical ground or electrical bonding to meet the code as part of the module to substructure attachment, with or without the addition of hardware.

[0071] The magnetic properties of steel can provide special features and benefits through the use of magnetic steel frames. The magnetic properties of steel can allow accessories to be simply attached with little or no additional hardware. The magnetic properties of steel can allow sensing devices to collect useful data or data about panel installation during the manufacture of the frame precursor structure. The magnetic properties of steel can allow robotic sensors to be used to assist in the proper installation or removal of panel modules. The magnetic properties of steel can allow various types of hardware to be easily attached or pre-attached to the module frame to facilitate the installation of additional equipment.

[0072] In some cases, the framework precursor structure can be made of a long sheet of a bendable and cuttable framework material. For example, depending on the framework material, a water cutter, a laser, a punch, a saw, etc. can be used to cut the long sheet. Cutting can be used to form some of the various features described herein, such as notches, holes, grooves or other features. After at least some cutting is performed, the long sheet can be folded to form at least part of the framework precursor structure. Such folding can include, but is not limited to, roll forming. In some embodiments, the cutting and folding process can be applied to the steel-based framework material of the coating.

[0073] Figure 5 5 is a schematic diagram showing a non-limiting example of a manufacturing line for manufacturing a frame precursor structure according to some embodiments. The manufacturing line 500 may include a frame material station 510, which has a frame material that can be supplied to the next station. In some embodiments, the frame material can be in the form of a sheet precut to the final desired length. In some embodiments, the frame material can be continuously supplied to the next station. For example, the frame material station 510 may include a roll 512 of coated steel 514. The coated steel 514 can be supplied to the punching station 520. For example, the punching station 520 can pull the coated steel 514 from the roll. In some embodiments, certain cutting and / or punching processes can be performed at the punching station 520 to cut and / or remove a predetermined portion of the frame material, thereby manufacturing a patterned frame material. In some embodiments, if such cutting has not been performed, the frame material can be cut to the desired length at the punching station. In some embodiments, the process can be controlled to a high tolerance. The punching station 520 may include a microprocessor 525 and machine software and / or firmware that may control the cutting. The punching station 520 may include one or more sensors 526 that provide data to the microprocessor, which may be used to monitor the punching process or identify defects. The microprocessor 525 may electronically communicate with another microprocessor or with an external computer for sending or receiving data or instructions. Such electronic communication may be performed via cables or wireless methods.

[0074] After the punching station 520, the patterned frame material, such as coated steel, etc., can be received by the roll forming station 530. The steel can be formed in a linear manner using multiple rollers, which provide a graded bending process to form the steel into a desired shape, such as a formed frame material. The design of the rollers, the order of the rollers, and the tolerances can be highly accurate and can produce a fully formed and stamped or even almost fully formed and stamped frame precursor structure. The roll forming station 530 may include a microprocessor 535 and machine software and / or firmware, which can control the roll forming. The roll forming station 530 may include one or more sensors 536, which provide data to the microprocessor, which can be used to monitor the bending and folding process or identify defects. The microprocessor 535 can communicate electronically with another microprocessor or with an external computer for sending or receiving data or instructions. This electronic communication can be performed by a cable or wireless method. In some embodiments, if such cutting has not yet been performed, the frame material can be cut to the desired length at the roll forming station. In some embodiments, the roll-forming station may include an adhesive application tool to apply a suitable adhesive to predetermined portions of the frame material while forming the frame material, for example, to help the formed frame material retain its shape.

[0075] After the roll forming station 530, the formed frame material, such as coated steel, can be received by the post-forming station 540. Some non-limiting examples of the post-forming process may include cutting the frame precursor structure into a certain length, polishing / deburring, cleaning, or even passing the frame precursor structure through a straightening roller or mold that can ensure product accuracy. The post-forming station 540 may include a microprocessor 545 and machine software and / or firmware that can control one or more post-forming processes. The post-forming station 540 may include one or more sensors 546, which provide data to the microprocessor, which can be used to monitor the post-forming process or identify defects or parts that exceed tolerances. These data can be fed back to the roll forming station 530 for active adjustment of the roll forming roller or adjusting roller. The post-forming station 540 may include a cleaning section. The microprocessor 545 can communicate electronically with another microprocessor or with an external computer for sending or receiving data or instructions. This electronic communication can be carried out by cable or wireless methods.

[0076] After post-forming station 540, a completed or even nearly completed frame precursor structure 560 may be received by finishing station 550. The frame precursor structure may be loaded into a shipping container and ready for delivery to, for example, a solar panel module production facility.

[0077] In some embodiments, the frame material may be processed in a generally linear or forward direction from one station to the next. In some embodiments, the direction of the frame material may be temporarily reversed within a station, for example, to repeat a particular step. In some embodiments, there may be multiple punching stations, roll forming stations, and / or post-forming stations.

[0078] For any of the above-mentioned stations, the one or more microprocessors can provide control signals to electromechanical motors, which can be responsible for moving the intermediate products along the production line. Depending on the process to be performed on the intermediate products, the software / firmware running on one or more microprocessors can specify various factors / parameters of production. For some non-limiting examples only, the microprocessor can specify the speed and / or direction of the intermediate products passing through a given station. In some embodiments, the microprocessor can specify when and / or how to shape, punch, cut, etc. intermediate products in order to affect the desired intermediate / final product. In some embodiments, the microprocessor can receive signals from one or more sensors for monitoring the manufacturing process, identifying defects or parts that exceed tolerances, or measuring some other useful characteristics of them when manufacturing intermediate products. For example, one or more optical or imaging sensors can provide data that allows the microprocessor to evaluate the manufacturing state and / or the quality of performing a specific production step. In some embodiments, if the quality is below standard, the microprocessor can send a status alarm signal to the system operator and / or another microprocessor. Other sensors can also be used to monitor the manufacturing state and / or quality control metrics. In addition to optical and imaging sensors, non-limiting examples of potentially useful sensors or components thereof may include: laser-based sensors, including but not limited to laser position sensors; vision systems, including but not limited to vision measurement and shape vision systems; contact sensors, including but not limited to contact position sensors; vibration sensors; thermal sensors; conductivity sensors; roughness sensors; profilometers; ultrasonic sensors; stress sensors, etc.

[0079] In some embodiments, the frame or frame-type panel structure can be attached to a support structure that can hold the frame or frame-type panel structure in a predetermined position. Such support structures and systems can take a variety of forms, but some non-limiting examples can include brackets, track mounts, pole mounts, tracking mounts, or non-tracking mounts, etc. In conjunction with the support structure, the frame or frame-type panel structure can be attached to its intended target, including but not limited to: attaching to a building (e.g., a roof, wall, awning, etc.); attaching to the ground; attaching to a shading structure or parking space; or attaching to a mobile or stationary vehicle. In some embodiments, the frame or frame-type panel structure can be directly attached to its intended target without the need for an intermediate support structure. In this case, the target itself can be used as a support structure.

[0080] In order to provide sturdy support and strength for framed panels such as solar panels, it may be useful for the frame to include one or more connecting features, for example, when forming corner joints between frame precursor structures or portions. For describing the various features and techniques below, frames, frame precursor structures, and frame portions may be used interchangeably unless otherwise noted. In some cases, the frame may also include additional reinforcement features, such as crossbars that may extend from one frame portion to an opposing or adjacent frame portion. These additional reinforcement features may also benefit from the use of one or more connecting features. Similarly, in some embodiments, certain connecting features may be used to attach the framed panel structure to a supporting structure, such as a bracket.

[0081] In some embodiments, FIG. 1- Figure 3 The frames or frame portions shown may benefit from additional structural support features, such as frame support substructures, to improve the strength of the frame in a manner that may address the various forces that may be experienced when used in a framed panel structure. For example, such additional support may enable the frame to hold larger panels (e.g., PV laminate panels), withstand greater environmental and / or handling forces (e.g., wind, snow, mounting, clamping, bending, torsional stresses, etc.), or increase PV module life by reducing the number or strength of stress points or improving their distribution. In some cases, structural support features may enable the use of thinner, easier to handle, or less expensive frame materials.

[0082] In some embodiments, useful structural support features, such as frame support substructures, may include support walls that: (i) extend between the bottom flange and the frame sidewalls; (ii) extend between the bottom flange and the lower shelf; or (iii) include both (i) and (ii). In some cases, the frame portion or frame including the support walls, bottom flange, sidewalls, and lower shelf can be advantageously made from a single piece of frame material. In some cases, using a single piece of frame material for these features can simplify manufacturing, thereby reducing costs, and increasing production volume and yield. This single-piece manufacturing can also increase the life of the frame by avoiding many failure-prone connection points that would be required if these features were assembled from separate components.

[0083] There are many embodiments of useful frame parts including support walls. Fig. 6A is a perspective view of a cutaway portion of a non-limiting example of a frame portion including a support wall according to some embodiments. The axes of height H and length direction L are also shown for reference. Figure 6B yes Fig. 6A601, but labeled in a modified manner to clarify that any features may include multiple layers of frame material. Frame portion 601 may include frame material that has been cut and folded into a desired shape. Frame portion 601 may include a bottom flange 604 disposed at a base of the frame portion, and in some embodiments, bottom flange 604 may include multiple layers of frame material, such as bottom flange layers 604' and 604". Frame sidewalls 603 may be disposed at an outer portion of the frame portion and may be characterized by a height extending from the bottom flange. In some embodiments, longitudinal fold 602 may define an intersection of frame sidewall 603 and bottom flange 604, such as an intersection with bottom flange layer 604'. In some embodiments, longitudinal fold 602 may correspond to a bottom or base of frame sidewall 603. In some cases, the bottom of the frame sidewall may correspond to The panel containing structure should be at the end farthest from the panel containing structure. Although in some embodiments this may correspond to the folded portion 602, in an alternative design not shown in this figure, the frame side wall may extend below at least a portion of the bottom flange. However, typically, at least a portion of the frame side wall may extend upward above the bottom flange. The panel containing structure can be disposed at an upper portion of the frame side wall. The panel containing structure can include at least a lower shelf 605 extending from the frame side wall, and may also include pocket walls 606, a top lip 607, and possibly even a pocket area 608 for containing panels. In some embodiments, some or all of the lower shelf 605 may include a multi-layer frame Material, such as lower shelf layers 605', 605", 605"'. In some embodiments, two or more lower shelf layers can be formed by a fold in the frame material at the upper portion of the frame side wall. In some cases, lower shelf layers 605" and 605"' formed by the frame material of the fold at the upper portion of the frame side wall can be characterized as a panel receiving support feature, and lower shelf layer 605' is located on the panel receiving support feature. In some embodiments, the top lip can be formed by multiple layers of frame material, such as top lip layer 607' and top lip layer 607", and top lip layer 607' and top lip layer 607" can be formed by the top lip fold 637 is formed to form a multi-layer rounded top lip edge. The support wall 632 can be set in the inner part of the frame portion (relative to the inner part of the frame side wall). In some embodiments, the support wall 632 can extend between the bottom flange and the lower shelf. In some embodiments, the frame portion may include a reverse flange fold 639 so that the portion 604' of the bottom flange may include a double layer of frame material. In some embodiments, another longitudinal fold 631 may define the intersection of the support wall 632 and the bottom flange structure, for example, the intersection with portion 604'. In some cases, the longitudinal fold 633 may define the intersection of the support wall and the lower shelf 605.

[0084] Figure 6C 601. FIG. 602 is a plan view of a non-limiting example of a portion of a frame material 640 prior to any cutting, punching, or folding operations that may be used to make the frame portion 601. The longitudinal dimensions of the frame material are shown as a first edge E1 and a second edge E2, which are also shown in FIG. Fig. 6A and Figure 6B In some embodiments, Fig. 6A and Figure 6B As shown, E1 may correspond to the end of the upper lip layer 607 ″ and E2 may correspond to the end of the lower shelf layer 605 ′.

[0085] Fig.6D 6 is a cross-sectional view of a non-limiting example of a framed panel structure according to some embodiments. The framed panel structure 600 may include various frame portions as described above, such as a frame portion 601-2 and an opposing frame portion 601-4. In some embodiments, each frame portion may include: frame side walls 603-2, 603-4; bottom flanges 604-2, 604-4; lower shelves 605-2, 605-4; pocket walls 606-2, 606-4; top lips 607-2, 607-4 and support walls 632-2, 632-4. Panel 690 may be received on each lower shelf, such as in a portion of each pocket area (the pocket area may be formed by the lower shelf, the pocket wall and the top lip), and may be optionally secured in place using a sealant (not shown) that may have adhesive properties. The frame side walls of the frame portion may be characterized by being disposed at an outer portion of the frame portion, while the support walls of the same frame portion may be characterized by being disposed at an inner portion of the frame portion. In some embodiments, the outer portion may include a frame side wall that may be generally disposed away from the center of the panel relative to the support wall position. In some embodiments, the inner portion may be relative to the frame side wall position and the support wall may be generally disposed closer to the center of the panel. The outer portion and the inner portion may be relative terms relative to the frame side walls and the support wall, and do not necessarily mean the outermost or innermost portion of the frame portion (although this may be the case in some embodiments). As used herein, the term "outward" may refer to a direction generally away from the center of the panel or the intended center of the panel, and the term "inward" may refer to a direction generally toward the center of the panel or the intended center of the panel. The term "downward" herein may refer to a direction generally away from the plane of the panel and / or toward the base area of ​​the frame, and the term "upward" herein may refer to a direction generally toward the plane of the panel and / or away from the base area of ​​the frame.

[0086] With similar Fig. 6A or Figure 6BA frame or frame precursor structure of a frame cross section of may sometimes be referred to herein as a box frame, wherein the bottom flange, frame sidewalls, lower shelf, and support wall together form a closed structure in cross section, in which case one closed structure has four sides. However, a box frame may be applied to any frame portion that forms any closed shape in cross section. In some embodiments, the closed shape may include at least a bottom flange, frame sidewalls, and support walls, and have three or more distinct sides in cross section.

[0087] Despite Figure 6A-6D 605, but in some embodiments, the panel containment structure may include only the lower shelf 605, which may be a panel support shelf. In some cases, the panel containment structure may include pocket walls 606 but not the top lip 607. The pocket walls may sometimes be referred to as panel stops.

[0088] In some embodiments, the frames in the modules may be attached to bracket rails (support structures).

[0089] Fig. 7A 7 is a cross-sectional view of a portion of a solar panel mounting system according to some embodiments. The mounting system 750 includes a support structure 773 having a first shelf 777a that defines a first plane 775a of a first frame portion 701a for supporting a first solar panel module (for clarity, the solar panel and other frame portions are not shown, but may alternatively be shown as Figure 1B or Fig.6D The support structure 773 also includes a second shelf 777b defining a second plane 775b of a second frame portion 701b for supporting a second solar panel module (for clarity, the solar panels and other frame portions are not shown, but may alternatively be as shown). Figure 1B or Fig.6DAs shown, or with some other structure). The support structure 773 may include a partition structure 774, which is arranged between the first shelf and the second shelf and extends above the first plane and the second plane. In this embodiment, the partition structure includes a first retaining folding portion 779a and a second retaining folding portion 779b, respectively. The support structure 773 may include a first shelf flip-up portion 780a, which is arranged at the end of the first shelf 777a away from the partition structure 774 and extends above the first plane 775a. Similarly, the support structure 773 may include a second shelf flip-up portion 780b, which is arranged at the end of the second shelf 777b away from the partition structure 774 and extends above the second plane 775b. The support structure may also include one or more removable locking tabs for engaging the first frame portion and the second frame portion. There are many ways to provide locking tabs. In some embodiments, one or more locking tabs may be provided in i) the partition structure, ii) the first shelf upper flip, or both (i) and (ii) for engaging the first bottom flange portion of the first frame portion. Similarly, one or more second movable locking tabs may be provided in i) the partition structure, ii) the second shelf upper flip, or both (i) and (ii) for engaging the second bottom flange portion of the second frame portion.

[0090] In some embodiments, the support structure may be formed at least in part from a sheet of support structure material that has been cut and folded into a desired shape. The support structure material should have sufficient strength to support the solar panel module. In some embodiments, the support structure material may include: a metal such as uncoated steel, uncoated steel, stainless steel, aluminum; or another metal or metal alloy (possibly coated or uncoated), etc. In general, the material for the support structure may be selected from any of those materials described elsewhere for the frame material.

[0091] Figure 7B 701 is a cross-sectional view of a non-limiting example of a frame portion according to some embodiments. The structure of the frame portion 701 can be applied to the first frame portion or the second frame portion. The frame portion 701 may include a frame sidewall 703, a support wall 732, a shelf 705, a pocket area 708, and a bottom flange 704. The bottom flange 704 may include a portion 782 extending outward from the frame sidewall 732, which may be referred to as an outer flange extension 782 in this article. The bottom flange may include a portion 781 extending inwardly beyond the support wall 732, and this portion may be referred to as an inner flange extension 781 here.

[0092] like Figure 7BAs shown, the bottom flange 704 on the frame portion 701b can rest on the top of the support shelf 777b, and the bottom flange 704 on the frame portion 701a can rest on the top of the support shelf 777a.

[0093] Reference again Fig. 7A , the retaining folds 779a and 779b of the partition structure can be angled to allow retention or engagement with the outer flange extension 782. The locking tab 778a can be disposed in the first shelf upper flip 780a, and the locking tab 778b can be disposed in the second shelf upper flip 780b. In operation, the locking tabs 778a, 778b can move (e.g., fold, rotate, bend, etc.) on the corresponding inner flange extensions 781 of the corresponding first frame portion and the second frame portion and abut against the corresponding inner flange extensions 781 of the corresponding first frame portion and the second frame portion, which can force each corresponding bottom flange 704 to abut against the support shelves 777a and 777b. This can help the frame portions 701a and 701b to be firmly retained and attached to the support structure 773.

[0094] The retaining fold is shown as a folded structure, but it can be any structural shape that can retain the outer flange extension. The outer flange extension 782 is shown as a frame portion continuous fold. The inner flange extension 781 is shown as a frame portion end fold attachment. The frame portion continuous fold can be on either side of the frame portion. The frame portion continuous fold can be on both sides of the frame portion.

[0095] As shown, locking tabs 778a and 778b can taper on the bottom. This can allow clearance to fit on the top of the inner flange extension 781. When these locking tabs rotate, the tapering shape can push the outer flange extension 782 under the retention fold 779a and 779b and against the retention fold 779a and 779b. The tilting of the retention fold 779a and 779b can help push the outer flange extension 782 against the support shelves 777a and 777b. The bottom tapering shape on the locking tabs 778a and 778b can produce high downward pressure on the top or top edge of the inner flange extension 781.

[0096] The support structure 773 may include a central support wall 774 extending below the first plane 775a and the second plane 775b. In some cases, the central support wall 774 may extend downward to the support base 772. Although not shown, there may be multiple support walls instead of a single central support wall, for example, one support wall is located below the first frame portion and another support wall is located below the second frame portion. The multiple support walls may also optionally extend to the support base. The shape of the support structure 773 is Fig. 7AAn I-beam is shown in FIG. This is a very strong shape, but the support structure is not limited to an I-beam shape, but can be any shape.

[0097] Figure 7C and Fig.7D are perspective cross-sectional views of some non-limiting examples of support structures according to some embodiments. The features of support structures 773C and 773D may be similar to those of Fig. 7A Those features shown, but for clarity, only the first shelf 777a area is shown in general view to illustrate some of the locking tab options. In some cases, the locking tab can be a door tab 778a, which is characterized by a pivot axis 788, which can be substantially orthogonal to the first plane (e.g., within 10 degrees of orthogonal). In some embodiments, the locking tab can be a fold-down tab 776a, which is characterized by a pivot axis 786, which can be substantially parallel to the first plane (e.g., within 10 degrees of parallel). Although not shown, the shelf flip-up portion 780a can include a spring tab arranged in a manner as described elsewhere herein. Figure 7C In the embodiment, there is an open space on each of the fold-down tab 776a and the door tab 778a. That is, there is no supporting structural material on the tab, and the tab extends all the way to the top of the shelf flip 780a. Fig.7D In the embodiment, the shelf upper flip 780a is taller, which does not show an open space above the tab. This taller shelf upper flip can allow for a harder and stronger tab because the shelf upper flip will not deflect as much when the corresponding tab is moved (pivoted). For convenience, Fig.7D This lug structure that is roughly surrounded by the supporting structure material can be referred to as a framed lug. In some embodiments, placing an additional folding portion at the top (end) of the shelf flip-up portion (not shown) can allow more locking lug forces, because the shelf flip-up portion can be even less deflected. This additional folding portion can be tilted toward or away from the partition structure. The shelf flip-up portion 780a is shown as forming an approximately right angle with the supporting shelf 777a, but it can also form different angles. In addition, although not shown, two frames can be adjacent to each other, rather than engaging with the partition structure. That is, in some cases, the partition structure may not exist and / or extend above the first plane and the second plane.

[0098] Fig. 8A A cross-sectional view of a portion of another solar panel mounting system is shown, according to some embodiments. Fig. 8A Some aspects of the installation system can be similar to Fig. 7AThe mounting system 850 may include a support structure 873 having a first shelf 877a defining a first plane 875a for supporting a first frame portion 701a of a first solar panel module. The support structure 873 also includes a second shelf 877b defining a second plane 875b for supporting a second frame portion 701b of a second solar panel. Additional features of the support structure 873 may be found in Figure 8B (section view) and Figure 8C (stereoscopic view). The support structure 873 may include a partition structure 874, which is disposed between the first shelf and the second shelf and extends above the first plane and the second plane. In this embodiment, the partition structure includes a first vertical wall 879a and a second vertical wall 879b, respectively. The support structure 873 may include a first shelf flip-up portion 869a, which is disposed at the end of the first shelf 877a away from the partition structure 874 and extends above the first plane 875a. In some cases, as shown in the figure, the first shelf flip-up portion can be folded at a certain angle relative to the first plane, so that a portion of the first shelf flip-up portion is disposed on an inner extension of the bottom flange of the first frame portion (see Figure 7B and related discussions of the framework in more detail). Fig. 8A and Figure 8B The folded first shelf flip-up portion shown here may also be referred to as shelf flip-back portion 869a. Similarly, the support structure 873 may include a second shelf flip-up portion 869b (also referred to as second shelf flip-back portion 869b) disposed at the end of the second shelf 877b away from the partition structure 874 and extending above the second plane 875b.

[0099] The support structure may also include one or more movable locking tabs for engaging the first frame portion and the second frame portion. Fig. 8A , the locking tab 884a can be set in the partition structure, such as in the first vertical wall 879a, and turned to engage the outer flange extension of the bottom flange of the first frame portion 701a, thereby holding or locking the bottom flange against the shelf. Similarly, the locking tab 884b can be set in the partition structure, such as in the second vertical wall 879a, and turned to engage the outer flange extension of the bottom flange of the second frame portion 701b, thereby holding or locking the bottom flange against the shelf. To more clearly illustrate the vertical walls, Figure 8B The locking tabs in the turned / bent position are not shown. The locking tabs 884a, 884b may be, for example, similar to Fig. 7A , Figure 7C and Fig.7DThe door tab of the locking tab 778 is shown. Figure 8C 873, showing locking tabs (door tabs) 884a and 884b in their moved (turned, bent, etc.) positions. A tool (not shown) may be used to bend the tabs. Note that the locking tabs 884a, 884b may alternatively be fold-down tabs or spring tabs, or a combination may be used. Although these figures show a first vertical wall and a second vertical wall, the partition structure may include a single vertical wall, and the locking tabs may alternatively be disposed in a single common vertical wall.

[0100] The support structure 873 may include a central support wall 874 extending below the first plane 875a and the second plane 875b. The central support wall 874 may optionally extend downward to the support base 872. Although not shown, there may be multiple support walls, for example, one support wall located below the first frame portion and another support wall located below the second frame portion, rather than a single central support wall. The multiple support walls may also optionally extend to the support base. The shape of the support structure 873 is Figure 8B This is a very strong shape, but the support structure is not limited to an I-beam shape and can be any shape.

[0101] Fig. 9C The use of wedge 987 to lock frame portion 901 to support structure 973 is shown. Fig.9A The frame portion 901 is shown above and ready to be inserted into the support structure 973. The inner flange upturn 985 shows a vertical wall. The wall can be inclined. The shelf hooks 986 show vertical walls. They can also be inclined.

[0102] exist Fig. 9B , the frame portion has been inserted and positioned for insertion of wedge 987. Fig. 9C The inserted wedge 987 is shown. Fig. 9B , the frame portion can sit on the support structure shelf 977. The wedge 987 can be tapered, which can allow the frame portion 901 to lift when the wedge 987 is inserted. The inner flange flip-up portion 985 can interlock to the shelf hook 986. The inner flange flip-up portion 985 and the shelf hook 986 can prevent the frame portion from being pulled out of the support structure.

[0103] Wedge 987 may also be a cam (not shown) or a rotating wedge (not shown). Fig.9DA support structure 973 is shown with a wider support shelf 977, which includes a first shelf 977a and a second shelf 977b. This prevents the first inserted frame portion from passing over (under) the support shelf 977. In some embodiments, the frame portion 901 can be initially positioned (before engaging the wedge) by positioning it at the end of the support structure 973 and sliding along the shelf 977.

[0104] The crossbars and end frame portions (not shown, but shown earlier in the description) may be shorter than the frame portion 901 so placed within the support structure. An alternative may be to cut out the shelf hooks 986 where the crossbars and end frame portions are located.

[0105] exist Fig. 7A , Figure 8B and Fig. 9C In the embodiment of the present invention, the support structure can be moved while the frame part is attached to the support structure. Fig. 10A , Fig. 11C and Fig. 12A Embodiments may not require movement of the support structure during attachment of the frame portions to the support structure.

[0106] Fig. 10A The use of wedges to lock a portion of the frame to the support structure 973 is shown. Figure 10B-10G Details of the frame portion 1001, wedge 1087 and support structure 1073 are shown. Fig. 10H Frame portion 1001 is shown on support shelf 1077 and in position prior to insertion of wedge 1087 through wedge hole 1088.

[0107] The wedge 1087 may taper on the ends to allow lifting of the frame portion when the wedge 1087 is inserted through the wedge hole 1088. Fig.10I The wedge 1087 is shown in place with the frame portion 1001 securely attached to the support structure 1073. Referring to the exploded view of FIG. 11J , the wedge can be wedged between the support shelf 1077 and the bottom flange 1004, which can force the upturned portion pocket 1091 against the hook end 1090. If the inner flange upturned portion 1085 is longer, the upturned portion top 1089 can be pressed against the hook underside 1092. Contact or both works well.

[0108] Fig.11A A cross-sectional view of a portion of another solar panel mounting system is shown, according to some embodiments. Fig.11A Some aspects of the installation system can be similar to Fig. 7A and / or Fig. 8AThe mounting system 1150 includes a support structure 1173 having a first shelf 1177a defining a first plane 1175a for supporting a first frame portion 701a of a first solar panel module. The support structure 1173 also includes a second shelf 1177b defining a second plane 1175b for supporting a second frame portion 701b of a second solar panel. Additional features of the support structure 1173 may be found in Fig. 11B (section view) and Fig. 11C (stereoscopic view). The supporting structure 1173 may include a partition structure 1174, which is arranged between the first shelf and the second shelf and extends above the first plane and the second plane. In this embodiment, the partition structure includes a first vertical wall 1179a and a second vertical wall 1179b, respectively. The supporting structure 1173 may include a first shelf flip-up portion 1180a, which is arranged at the end of the first shelf 1 away from the partition structure 1174 and extends above the first plane 1175a. Similarly, the supporting structure 1173 may include a second shelf flip-up portion 1180b, which is arranged at the end of the second shelf 1177b away from the partition structure 1174 and extends above the second plane 1175b.

[0109] The support structure may also include one or more movable locking tabs, in this case spring tabs, for engaging the first frame portion and the second frame portion. For example, spring tabs 1194a, 1194b may be provided in the shelf flip-up portions 1180a, 1180b for engaging the inner flange extensions of the bottom flanges of the frame portions 701a, 701b. In addition, spring tabs 1193a, 1193b may be provided in the partition structure 1174, in particular in the vertical walls 1179a, 1179b, for engaging the outer flange extensions of the frame portions 701a, 701b. Additional information about the frame portions may be found, for example, in Figure 7Band the related discussion of this article. With respect to installation, the frame portion of the solar panel module can be positioned on an appropriate support structure shelf and pushed downward. As shown, the spring tabs are not parallel to their respective vertical walls or shelf flips, but extend outward into the space to be occupied by the frame portion. Typically, the spring tabs may have a spring axis substantially parallel to the corresponding plane. For example, the spring tab 1194b may have a spring axis 1196 substantially parallel to the second plane 1175b, and the spring tab 1193a may have a spring axis 1195 substantially parallel to the first plane 1175a. The spring tabs can provide some initial resistance to the bottom flange, but can be moved by sufficient downward force. For example, the spring tabs 1193a, 1193b can be bent downward (the spring tab ends are bent toward the vertical walls 1179a, 1179b) to allow the outer extension of the bottom flange to pass under the bottom edge of the spring tab, and then the spring tabs bounce back into place to engage the outer flange extension of the bottom flange. Similarly, the spring tabs 1194a, 1194b can be bent downward (the ends of the spring tabs are bent toward the shelf flip-up portions 1180a, 1180b) to allow the inner flange extension of the bottom flange to pass under the bottom edge of the spring tabs, and then the spring tabs spring back into place, thereby engaging the inner extension of the bottom flange. Thus, in some cases, the module can be installed to the support structure in a simple step without the need for any tools. It should be noted that in some cases, the frame portion can be completely locked in place by the engagement of the spring tabs. In some cases, the engagement can be loose and used to roughly position the frame portion in a simple step, and another locking mechanism is provided to lock the frame portion more securely in place. Alternatively, even when the spring tabs provide a secure lock, another locking mechanism can be optionally added as an additional insurance for keeping the solar panel module in place. In some cases, the other locking mechanism may include a door tab or a downward folding tab as described elsewhere herein. In some cases, the other locking mechanism may include bolts, screws, etc.

[0110] Although the figures show a first vertical wall and a second vertical wall, the divider structure may include a single vertical wall, and the locking tabs may alternatively be provided in a single common vertical wall.

[0111] The support structure 1173 may include a central support wall 1174 extending below the first plane 1175a and the second plane 1175b. The central support wall 1174 may optionally extend downward to the support base 1172. Although not shown, there may be multiple support walls, for example, one support wall located below the first frame portion and another support wall located below the second frame portion, rather than a single central support wall. The multiple support walls may also optionally extend to the support base. The shape of the support structure 1173 is Fig. 11B An I-beam is shown in FIG. An I-beam is a very strong shape, but the support structure is not limited to an I-beam shape and can be any shape.

[0112] Fig.11D yes Fig.11A 3D view of the mounting system, but with fewer components labeled for clarity. It should be noted that Fig. 7A , Fig. 8A or Fig.11A The elements of the mounting system described in the drawings can be combined in various ways. Although not shown, the two frames can be adjacent to each other rather than engaging with the partition structure. That is, in some cases, the partition structure may not exist and / or extend above the first plane and the second, and only the spring tab is provided in the shelf upper flap.

[0113] Fig. 12A Attachment clips 1297 are shown that may attach the frame portion 1201 to the support structure 1273. Figure 12B-12F Details of the attachment clip 1297, frame portion 1201, and support structure 1273 are shown. Once the frame portion is in place, the attachment clip 1297 can be slid into place, such as Figure 12G-12H shown. Fig.12H It is shown that the clip edge 1299 may not press against the roll top 1275, and the lower flip end 1296 may not push against the lower clip contact portion 1272, which may allow the attachment clip 1297 to slide easily. The clip guide 1268 can be used to help position the assembly components and also prevent the frame portion from sliding out of the attachment clip.

[0114] Using a tool (not shown), a deforming force 1271 may be applied to permanently deform the attachment clip, such as Fig.12I -As shown in Figure K.

[0115] exist Figure 12K 1272. The force between the lower clip contact portion 1272 and the clip edge 1299 can forcibly push the clip edge 1299 into the roll top 1275, push the bottom flange 1204 against the support shelf 1277, and push the lower flap end 1296 against the lower clip contact portion 1272. This securely attaches the frame portion 1201 to the support structure 1273.

[0116] Another way to get the same result could be to Figure 12L The over-bent attachment clip shown is started. Now, a tool (not shown) can apply a spreading force 1270 to allow the attachment clip 1297 to slide into place. The tool can then be removed, which can allow the clip to attempt to return to its original shape, but will be stopped by the clip edge 1299 and the lower clip contact portion. The force generated can be an attachment clip as described in the previous paragraph.

[0117] The attachment clips shown slide into place, but the attachment clips can also be made so that they can be twisted into place at the desired position. The short slots can be located at the desired position of the clip.

[0118] If it is desired to remove the attachment clip, a screwdriver or other tool may be inserted into the clip flex hook 1298 which may pry and open the attachment clip so that the attachment clip may be removed.

[0119] For higher loads, more attachments can be used. Fig. 9B and Fig. 10A , this attachment can be continuous, thereby supporting higher loads.

[0120] Although the methods, apparatuses, and devices of the present application are described herein for use in manufacturing frames for solar panels, they can be used to manufacture many other products in many other fields. In some cases, such other products can be those formed at least in part from a generally flat starting material, including but not limited to metal sheets (coated or uncoated).

[0121] It should be noted that various components and frame features, including but not limited to frame sidewalls and bottom flanges, are generally shown as straight or flat in their respective figures, but in some embodiments, one or more of these features (or other features shown as straight or flat) may alternatively be non-straight or non-flat. For example, one or more of these features may include one or more curves or additional bends and still effectively perform their intended functions.

[0122] Also note that in any of the figures herein, a fold that may be represented as having a sharp corner may be replaced with a rounded corner. In some embodiments, a corner formed by a fold may be characterized by a bend radius.

[0123] In some embodiments, in areas where portions of the frame material may be in contact with another material, the area may optionally include an anti-corrosion coating or additional anti-corrosion coating treatments, which anti-corrosion coating or additional anti-corrosion coating treatments include but are not limited to those already discussed, wherein the other material includes but is not limited to another portion of the frame material, bolts, washers, supporting structures, etc.

[0124] In some embodiments, in areas where multiple layers of frame material are formed, such areas may optionally include bonding or attachment features that hold these layers together. Some non-limiting examples of attachment features may include crimps, clinch, interlocking features between layers, double-sided tape, adhesives, welds, brazes, solders, etc. In some embodiments, the anti-corrosion coating may also have adhesive properties and serve as an attachment feature.

[0125] Examples of implementation methods

[0126] Further embodiments herein include the following listed embodiments. In these listed embodiments, the term "including" (and variants thereof, "includes", "include") includes its normal meaning in addition to "comprising" ("comprises", "comprise") and / or "consisting of" ("consists of", "consist of") and / or "consisting essentially of" ("consists essentially of", "consists essentially of"), in addition to "comprising".

[0127] 1. A solar panel support structure, comprising:

[0128] a first shelf for supporting a first frame portion of a first solar panel module, the first shelf defining a first plane;

[0129] a second shelf for supporting a second frame portion of a second solar panel module, said second shelf defining a second plane;

[0130] a partition structure disposed between the first shelf and the second shelf and optionally extending above the first plane and the second plane;

[0131] a first shelf disposed at an end of the first shelf away from the partition structure and extending above the first plane;

[0132] a second shelf disposed at an end of the second shelf away from the partition structure and extending above the second plane;

[0133] one or more first movable locking tabs disposed in: i) the divider structure; ii) the first shelf upper flap; or both (i) and (ii) for engaging a first bottom flange portion of the first frame portion; and

[0134] One or more second movable locking tabs are disposed in: i) the divider structure; ii) the second shelf upper flap; or both (i) and (ii) for engaging the second bottom flange portion of the second frame portion.

[0135] 2. The support structure of embodiment 1, wherein the support structure is formed from a sheet of support structure material, and wherein the one or more first locking tabs and the one or more second locking tabs are formed from cutouts in the support structure material.

[0136] 3. A support structure according to embodiment 1 or 2, wherein at least one of the locking protrusions is a spring protrusion, and the spring protrusion has a spring axis, and the spring axis: i) is generally parallel to the first plane when the spring protrusion engages the first bottom flange portion; or ii) is generally parallel to the second plane when the spring protrusion engages the second bottom flange portion.

[0137] 4. A support structure according to any one of embodiments 1-3, wherein at least one of the locking tabs is a door tab, and the door tab has a pivot axis, and the pivot axis: i) is substantially orthogonal to the first plane when the door tab engages the first bottom flange portion; or ii) is substantially orthogonal to the second plane when the door tab engages the second bottom flange portion.

[0138] 5. The support structure according to embodiment 4, wherein the door tab has a gradually tapering structure.

[0139] 6. A support structure according to any one of embodiments 1-5, wherein at least one of the locking tabs is a downward folding tab, and the downward folding tab has a pivot axis, and the pivot axis: i) is substantially parallel to the first plane when the downward folding tab engages the first bottom flange portion; or ii) is substantially parallel to the second plane when the downward folding tab engages the second bottom flange portion.

[0140] 7. A support structure according to any one of embodiments 1 to 6, wherein the first plane is substantially equal to the second plane.

[0141] 8. The support structure according to any one of embodiments 1-7 also includes a central support wall, which extends below the partition structure and below the first plane and the second plane.

[0142] 9. A support structure according to embodiment 8, wherein the central support wall extends to a support base.

[0143] 10. The support structure of embodiment 8 or 9, wherein the support structure has an I-beam shape.

[0144] 11. A support structure according to any one of embodiments 1-10, wherein the separating structure includes a first retaining folding portion, which is arranged at a certain angle relative to the first plane so that a portion of the first retaining folding portion is positioned above an outer flange extension of the first bottom flange portion.

[0145] 12. The support structure of embodiment 11, wherein the first shelf upper flip includes one or more locking tabs for engaging an inner flange extension of the first bottom flange portion.

[0146] 13. The support structure of embodiment 12, wherein the one or more locking tabs of the first shelf upper flip include door tabs, fold-down tabs, spring tabs, or any combination thereof.

[0147] 14. A supporting structure according to any one of embodiments 11-13, wherein the separating structure further comprises a second retaining folding portion, wherein the second retaining folding portion is arranged at a certain angle relative to the second plane so that a portion of the second retaining folding portion is positioned above an outer flange extension portion of the second bottom flange portion.

[0148] 15. The support structure of embodiment 14, wherein the second shelf upper flip includes one or more locking tabs for engaging an inner flange extension of the second bottom flange portion.

[0149] 16. The support structure of embodiment 15, wherein the one or more locking tab flip-up portions of the second shelf include door tabs, fold-down tabs, spring tabs, or any combination thereof.

[0150] 17. A support structure according to any one of embodiments 1-10, wherein the partition structure includes a first vertical wall having one or more locking tabs, and the one or more locking tabs are used to engage the outer flange extension of the first bottom flange portion.

[0151] 18. The support structure of embodiment 17, wherein the one or more locking tabs of the first vertical wall comprise a door tab, a fold-down tab, a spring tab, or any combination thereof.

[0152] 19. The support structure according to embodiment 17 or 18, wherein the first flip-up portion is folded at a certain angle relative to the first plane so that a portion of the first flip-up portion is positioned above the inner flange extension of the first bottom flange portion.

[0153] 20. The support structure of any one of embodiments 17-19, wherein the divider structure comprises a second vertical wall having one or more locking tabs for engaging an outer flange extension of the second bottom flange portion.

[0154] 21. The support structure of embodiment 20, wherein the one or more locking tabs of the second vertical wall comprise a door tab, a fold-down tab, a spring tab, or any combination thereof.

[0155] 22. A support structure according to embodiment 20 or 21, wherein the first vertical wall and the second vertical wall are the same wall.

[0156] 23. A support structure according to any one of embodiments 20-22, wherein the second flip-up portion is folded at a certain angle relative to the second plane so that a portion of the second flip-up portion is positioned above the inner flange extension of the second bottom flange portion.

[0157] 24. A support structure according to any one of embodiments 11-13, wherein the partition structure includes a vertical wall having one or more locking tabs, wherein the locking tabs are used to engage the outer flange extension of the second bottom flange portion.

[0158] 25. The support structure of embodiment 24, wherein the one or more locking tabs of the vertical wall comprise a door tab, a fold-down tab, a spring tab, or any combination thereof.

[0159] 26. A support structure according to embodiment 24 or 25, wherein the second flip-up portion is folded at a certain angle relative to the second plane so that a portion of the second flip-up portion is positioned above the inner flange extension of the second bottom flange portion.

[0160] 27. A supporting structure according to any one of embodiments 1-10, wherein the partition structure includes a first vertical wall having one or more spring protrusions, wherein the spring protrusions are used to engage the outer flange extension of the first bottom flange portion, and wherein the first shelf upper flip portion includes one or more spring protrusions, wherein the spring protrusions are used to engage the inner flange extension of the first bottom flange portion.

[0161] 28. The support structure according to embodiment 27 further comprises one or more locking protrusions in addition to the spring protrusions, wherein the spring protrusions are arranged in: i) the first vertical wall; ii) the first shelf; or iii) both (i) and (ii).

[0162] 29. A support structure according to embodiment 27 or 28, wherein the partition structure includes a second vertical wall having one or more spring protrusions for engaging the outer flange extension of the second bottom flange portion, and wherein the second shelf upper flip portion includes one or more spring protrusions for engaging the inner flange extension of the second bottom flange portion.

[0163] 30. The support structure according to embodiment 29 further comprises one or more locking protrusions in addition to the spring protrusions, wherein the spring protrusions are arranged in: i) the second vertical wall; ii) the second shelf; or iii) both (i) and (ii).

[0164] 31. A support structure according to embodiment 29 or 30, wherein the first vertical wall and the second vertical wall are the same wall.

[0165] 32. The support structure of any one of embodiments 1-30, wherein the first frame portion and the second frame portion each comprise:

[0166] an elongated piece of frame material having a first end and a second end, wherein the first end and the second end define a longitudinal dimension;

[0167] a longitudinal fold defining an intersection of a frame side wall and a bottom flange, wherein at least a portion of the frame side wall extends above the bottom flange, and wherein the bottom flange further comprises: i) an inner flange extension; ii) an outer flange extension; or iii) both (i) and (ii); and

[0168] A panel receiving structure is located at an upper portion of the frame side wall, the panel receiving structure including a lower shelf extending from the side wall, wherein the panel receiving structure engages a bottom surface of a corresponding solar panel.

[0169] 33. A solar panel mounting system comprising:

[0170] A first frame portion of a first solar panel module and a second frame portion of a second solar panel module, each frame portion comprising:

[0171] an elongated piece of frame material having a first end and a second end, wherein the first end and the second end define a longitudinal dimension,

[0172] a longitudinal fold defining an intersection of a frame side wall and a bottom flange, wherein at least a portion of the frame side wall extends above the bottom flange, and wherein the bottom flange further comprises a flange upturn disposed at an end of: i) an inner flange extension; ii) an outer flange extension; or iii) (i) and (ii)

[0173] Both; and

[0174] a panel containment structure at an upper portion of the frame sidewall, the panel containment structure comprising a lower shelf extending from the sidewall, wherein the panel containment structure engages a bottom surface of a corresponding solar panel;

[0175] The supporting structure comprises:

[0176] a first shelf for temporarily supporting the first frame portion, the first shelf defining a first plane;

[0177] a second shelf for temporarily supporting the second frame portion, the second shelf defining a second plane;

[0178] a first shelf hook disposed at an end of the first shelf and extending above the first plane for engaging a flanged upturned portion of the first frame portion, wherein

[0179] The first shelf hook includes a first wedge hole; and

[0180] a second shelf hook disposed at an end of the second shelf and extending above the second plane for engaging a flanged upturned portion of the second frame portion, wherein

[0181] The second shelf hook includes a second wedge hole; and

[0182] A wedge-shaped member capable of being positioned between the bottom flange of the first frame portion and the first shelf and between the bottom flange of the second frame portion and the second shelf, wherein the thickness of the wedge-shaped member is sufficient to cause a first locking engagement between the upturned portion of the first frame flange and the first shelf hook and a second locking engagement between the upturned portion of the second frame flange and the second shelf hook.

[0183] 34. A method of installing a solar panel using the mounting system of embodiment 33, the method comprising:

[0184] positioning the first frame portion on the first shelf;

[0185] positioning the second frame portion on the second shelf;

[0186] Inserting a wedge through the first wedge hole and the second wedge hole forces the first frame portion and the second frame portion upward, thereby causing the first locking engagement and the second locking engagement.

[0187] 35. The method of embodiment 34, wherein positioning the first frame portion comprises sliding a bottom flange of the first frame portion along the first shelf, and wherein positioning the second frame portion comprises sliding a bottom flange of the second frame portion along the second shelf.

[0188] 36. A solar panel mounting system comprising:

[0189] A first frame portion of a first solar panel module and a second frame portion of a second solar panel module, each frame portion comprising:

[0190] an elongated piece of frame material having a first end and a second end, wherein the first end and the second end define a longitudinal dimension;

[0191] a longitudinal fold defining an intersection of a frame side wall and a bottom flange, wherein at least a portion of the frame side wall extends above the bottom flange, and wherein the bottom flange further comprises an outer flange extension;

[0192] a panel receiving structure at an upper portion of the frame sidewall, the panel receiving structure comprising a lower shelf extending from the sidewall, wherein the panel receiving structure engages a bottom surface of a corresponding solar panel,

[0193] The supporting structure comprises:

[0194] a first shelf for supporting the first frame portion, the first shelf defining a first plane;

[0195] a second shelf for supporting the second frame portion, the second shelf defining a second plane;

[0196] A first shelf flip-down portion, disposed at an end of the first shelf and extending below the first plane; and

[0197] a second shelf flip-down portion, disposed at an end of the second shelf and extending below the second plane, wherein the second shelf is close to the first shelf flip-down portion, and a space between the first shelf flip-down portion and the second shelf flip-down portion; and

[0198] An attachment clip is positionable in the space and includes: i) a first lower clip contact portion for engaging the first shelf flip-down portion; ii) a second lower clip contact portion for engaging the second shelf flip-down portion; iii) a first clip edge for engaging the first frame portion outer flange extension; and iv) a second clip edge for engaging the second frame portion outer flange extension.

[0199] 37. A method of installing a solar panel using the mounting system of embodiment 36, the method comprising:

[0200] positioning a first frame portion on said first shelf;

[0201] positioning the second frame portion on the second shelf;

[0202] Sliding the attachment clip into the space so that the first and second lower clip contact portions are adjacent to the first and second shelf flip-down portions, and the first and second clip edges are adjacent to the first and second frame portion outer flange extensions; and

[0203] The clip is deformed so that the lower clip contact portion engages the shelf flip-down portion and the clip edge engages the outer flange extension.

[0204] Without departing from the spirit and scope of the embodiments, the specific details of a particular embodiment may be combined in any suitable manner. However, other embodiments may relate to specific embodiments related to each individual aspect, or specific combinations of these individual aspects.

[0205] The above description of exemplary embodiments has been presented for purposes of illustration and description. It is not intended to be exhaustive or to limit the embodiments to the precise form described, and many modifications and variations are possible in light of the above teachings.

[0206] In the foregoing description, for the purpose of explanation, many details have been set forth in order to provide an understanding of various embodiments of the present technology. However, it is apparent to those skilled in the art that certain embodiments may be practiced without some of these details or with additional details.

[0207] Several embodiments have been described, and those skilled in the art will recognize that various modifications, alternative structures, and equivalents may be used without departing from the spirit of the embodiments. In addition, in order to avoid unnecessarily obscuring the present embodiments, many well-known processes and elements are not described. In addition, the details of any particular embodiment may not always be present in a variation of that embodiment, or may be added to other embodiments.

[0208] It should be understood that, in the case of providing a numerical range, unless the context clearly stipulates otherwise, each intermediate value between the upper and lower limits of the range to one tenth of the unit of the lower limit is also specifically disclosed. Each smaller range between any of the values ​​or intermediate values ​​in the range and any other values ​​or intermediate values ​​in the range is included. The upper and lower limits of these smaller ranges can be independently included or excluded in the range, and each range including any one, two or two limits in a smaller range is also included in the embodiment, subject to the limitation of any special excluded limits in the range. When the range includes one or two of the limits, it also includes the range that does not include one or two of those included limits.

[0209] As used herein and in the appended claims, the singular forms "a," "an," and "the" include plural referents unless the context clearly dictates otherwise. Thus, for example, reference to "a method" includes a plurality of such methods, and reference to "a battery cell" includes reference to one or more battery cells and equivalents thereof known to those skilled in the art, and so forth. The present application has now been described in detail for purposes of clarity and understanding. However, it should be understood that certain changes and modifications may be made within the scope of the appended claims.

[0210] All publications, patents, and patent applications cited herein are incorporated by reference in their entirety for all purposes. No admission is made that these publications, patents, and patent applications are prior art.

Claims

1. A solar panel support structure, comprising: a first shelf for supporting a first frame portion of a first solar panel module, the first shelf defining a first plane; a second shelf for supporting a second frame portion of a second solar panel module, said second shelf defining a second plane; a partition structure disposed between the first shelf and the second shelf and extending above the first plane and the second plane; A first shelf upper flip portion, disposed at an end of the first shelf away from the partition structure and extending above the first plane; A second shelf upper flip portion, disposed at an end of the second shelf away from the partition structure and extending above the second plane; one or more movable first locking tabs disposed in: i) the partition structure; ii) in the upper flip portion of the first shelf; or (i) and (ii), a first bottom flange portion for engaging the first frame portion; as well as one or more movable second locking tabs disposed in: i) the partition structure; ii) in the second shelf upper flap; or in both (i) and (ii) for engaging the second bottom flange portion of the second frame portion.

2. The support structure according to claim 1, wherein: The support structure is formed from a sheet of support structure material, and wherein the one or more first locking tabs and the one or more second locking tabs are formed from cutouts in the support structure material.

3. The support structure according to claim 1, wherein: At least one of the locking tabs is a spring tab having a spring axis that is: i) substantially parallel to the first plane when the spring tab engages the first bottom flange portion; or ii) substantially parallel to the second plane when the spring tab engages the second bottom flange portion.

4. The support structure according to claim 1, wherein: At least one of the locking tabs is a door tab having a pivot axis that is: i) substantially orthogonal to the first plane when the door tab engages the first bottom flange portion; or ii) substantially orthogonal to the second plane when the door tab engages the second bottom flange portion.

5. The support structure according to claim 4, wherein: The door tab has a tapered structure.

6. The support structure according to claim 1, wherein: At least one of the locking tabs is a fold-down tab having a pivot axis that: i) is substantially parallel to the first plane when the fold-down tab engages the first bottom flange portion; or ii) substantially parallel to said second plane when said folded downward tab engages said second bottom flange portion.

7. The support structure according to claim 1, wherein: The first plane is substantially equal to the second plane.

8. The support structure of claim 1 further comprising a central support wall extending below the divider structure and below the first plane and the second plane.

9. The support structure according to claim 8, wherein: The central support wall extends to a support base.

10. The support structure according to claim 8, wherein: The support structure has an I-beam shape.

11. The support structure according to claim 1, wherein: The divider structure includes a first retention fold disposed at an angle relative to the first plane such that a portion of the first retention fold is positioned above an outer flange extension of the first bottom flange portion.

12. The support structure according to claim 11, wherein: The first shelf upper flip includes one or more locking tabs for engaging an inner flange extension of the first bottom flange portion.

13. The support structure according to claim 12, wherein: The one or more locking tabs of the first shelf upper flip-up portion include door tabs, fold-down tabs, spring tabs, or any combination thereof.

14. The support structure according to claim 11, wherein: The divider structure also includes a second retention fold disposed at an angle relative to the second plane such that a portion of the second retention fold is positioned above an outer flange extension of the second bottom flange portion.

15. The support structure of claim 14, wherein: The second shelf upper flip includes one or more locking tabs for engaging an inner flange extension of the second bottom flange portion.

16. The support structure of claim 15, wherein: The one or more locking tabs of the second shelf upper flip-up portion include door tabs, fold-down tabs, spring tabs, or any combination thereof.

17. The support structure of claim 1, wherein: The divider structure includes a first vertical wall having one or more locking tabs for engaging an outer flange extension of the first bottom flange portion.

18. The support structure of claim 17, wherein: The one or more locking tabs of the first vertical wall include a door tab, a fold-down tab, a spring tab, or any combination thereof.

19. The support structure of claim 17, wherein: The first flip-up portion is folded at an angle relative to the first plane such that a portion of the first flip-up portion is positioned above an inner flange extension of the first bottom flange portion.

20. The support structure of claim 17, wherein: The divider structure includes a second vertical wall having one or more locking tabs for engaging an outer flange extension of the second bottom flange portion.

21. The support structure of claim 20, wherein: The one or more locking tabs of the second vertical wall include a door tab, a fold-down tab, a spring tab, or any combination thereof.

22. The support structure of claim 20, wherein: The first vertical wall and the second vertical wall are the same wall.

23. The support structure of claim 20, wherein: The second flip-up portion is folded at an angle relative to the second plane such that a portion of the second flip-up portion is positioned above an inner flange extension of the second bottom flange portion.

24. The support structure of claim 11, wherein: The divider structure includes a vertical wall having one or more locking tabs for engaging an outer flange extension of the second bottom flange portion.

25. The support structure of claim 24, wherein: The one or more locking tabs of the vertical wall include a door tab, a fold-down tab, a spring tab, or any combination thereof.

26. The support structure of claim 24, wherein: The second flip-up portion is folded at an angle relative to the second plane such that a portion of the second flip-up portion is positioned above an inner flange extension of the second bottom flange portion.

27. The support structure of claim 1, wherein: The partition structure includes a first vertical wall having one or more spring tabs, wherein the one or more spring tabs are used to engage the outer flange extension of the first bottom flange portion, and wherein the first shelf upper flip portion includes one or more spring tabs, wherein the one or more spring tabs are used to engage the inner flange extension of the first bottom flange portion.

28. The support structure of claim 27, wherein: Also included is one or more locking tabs in addition to the spring tab, the one or more locking tabs: i) disposed in the first vertical wall; ii) disposed in said first shelf; or iii) is set in both (i) and (ii).

29. The support structure of claim 27, wherein: The divider structure includes a second vertical wall having one or more spring tabs for engaging an outer flange extension of the second bottom flange portion, and wherein the second shelf upper flip includes one or more spring tabs for engaging an inner flange extension of the second bottom flange portion.

30. The support structure of claim 29, wherein: Also included is one or more locking tabs in addition to the spring tab, the one or more locking tabs: i) disposed in the second vertical wall; ii) disposed in the second shelf upper flap; or iii) disposed in both (i) and (ii).

31. The support structure of claim 29, wherein: The first vertical wall and the second vertical wall are the same wall.

32. The support structure of claim 1, wherein: The first frame portion and the second frame portion each include: an elongated piece of frame material having a first end and a second end, wherein the first end and the second end define a longitudinal dimension; a longitudinal fold defining an intersection of a frame side wall and a bottom flange, wherein at least a portion of the frame side wall extends above the bottom flange, and wherein the bottom flange further comprises: i) an inner flange extension; ii) an outer flange extension; or iii) both (i) and (ii); and A panel receiving structure is located at an upper portion of the frame side wall, the panel receiving structure including a lower shelf extending from the side wall, wherein the panel receiving structure engages a bottom surface of a corresponding solar panel.

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