Adjustable mounting assembly for trapezoidal ribs attached to metal panels

Abstract

A mounting assembly configured to engage a trapezoidal rib extending from a metal panel is disclosed. The mounting assembly includes a mounting bracket and a PV mount. The mounting bracket includes a base including a first leg and a second leg adjustably connected by a bolt. Each leg has a foot having an aperture for receiving a shaft of a fastener that can extend through a sidewall of the trapezoidal rib when the mounting bracket is secured to the trapezoidal rib. The distance between the two feet can be adjusted by loosening the bolts so as to be matched with trapezoidal ribs of different sizes. The PV mount may be selectively connected to the base by bolts. In some embodiments, a photovoltaic mount includes at least one platform for a photovoltaic module.

Description

[0001] Cross-references to related applications

[0002] This application claims priority to U.S. Provisional Patent Application No. 63 / 623,045, filed January 19, 2024, pursuant to 35 USC § 119(e); and to U.S. Provisional Patent Application No. 63 / 579,711, filed August 30, 2023, the entire contents of which are incorporated herein by reference. Technical Field

[0003] The present invention generally relates to systems, methods, apparatus and components for mounting structures on building surfaces, and more specifically, to a mounting assembly that is adjustable to accommodate metal panels with trapezoidal ribs having various sizes and geometries. Background Technology

[0004] Metal panels are frequently used to define building surfaces, such as roofs and sidewalls. One type of metal panel is the trapezoidal rib panel. A trapezoidal rib panel may include one or more trapezoidal ribs. Each trapezoidal rib includes a top wall, which is typically flat or planar. A pair of sidewalls extend obliquely downwards from the top wall to base sections on either side of the rib.

[0005] It is often desirable to install various types of structures and attachments on building surfaces that include trapezoidal ribs. For example, snow barriers or blocks, signs, banners, lighting fixtures, pipes, antennas, roof walkways, lightning protection systems, condensate lines, chimney / flue supports, finishes, equipment screens, electrical conduits and wiring, heating, air conditioning, ventilation equipment, and photovoltaic or solar modules can be mounted on metal panels using mounting assemblies that engage with trapezoidal ribs. However, trapezoidal ribs are manufactured by many different companies and come in a variety of sizes and geometries. Mounting assemblies configured to engage a first trapezoidal rib having a first geometry often cannot reliably (or securely) attach to a second trapezoidal rib having a second geometry different from the first geometry.

[0006] Therefore, a mounting bracket is needed that is adjustable to accommodate various trapezoidal ribs with different profiles and sizes. Summary of the Invention

[0007] One aspect of this disclosure is an adjustable mounting bracket comprising a first leg movably interconnected to a second leg via a shaft of fasteners. The first leg is movable relative to the shaft and the second leg to facilitate adjustment of the mounting bracket for mounting on multiple different trapezoidal rib profiles with different configurations and / or dimensions. In one embodiment, in a first configuration, the minimum width between the first foot of the first leg and the second foot of the second leg is approximately 0.67 inches (17.04 mm). In a second configuration, the minimum width between the first and second feet is approximately 3.75 inches (95.18 mm).

[0008] In at least one embodiment, the first leg and the second leg are each formed from a single piece of metal. Therefore, the first leg and the second leg can be described as a single-piece construction (e.g., multiple components are not individually attached, welded, or combined to define the first leg or the second leg). Thus, in at least some embodiments, the first leg and the second leg do not include any seam joints between their adjacent portions.

[0009] The first and second legs of the adjustable mounting bracket in the first aspect are formed of a metallic material. In some embodiments, the metallic material is an aluminum alloy. However, other metal alloys can be used to form the adjustable mounting bracket.

[0010] In one embodiment, the first and second legs are formed from a roll of metal material. In at least one embodiment, the metal material is approximately 0.125 inches (3.175 mm) thick. The legs are formed by progressive stamping and forming operations as the roll of metal material is indexed through a forming apparatus.

[0011] Another aspect of this disclosure relates to a mounting bracket with an adjustable width to engage a trapezoidal rib projecting from a building surface. The mounting bracket includes a first leg and a first foot. The first leg has a first flange with a first orifice. The first foot is connected to the first flange via a first bend. The first foot includes a first outer surface, a first inner surface opposite to the first outer surface, and a first orifice extending through the first inner and first outer surfaces. A first portion of the first inner surface faces a first rib sidewall of the trapezoidal rib when the mounting bracket is secured to the trapezoidal rib. The mounting bracket includes a second leg and a second foot. The second leg has a second flange with a second orifice. The second foot is connected to the second flange via a second bend. The second foot includes a second outer surface, a second inner surface opposite to the second outer surface, and a second orifice extending through the second inner and second outer surfaces. A first portion of the second inner surface faces a second rib sidewall of the trapezoidal rib when the mounting bracket is secured to the trapezoidal rib. The mounting bracket includes a fastener comprising a shaft operable to extend through the first and second orifices to interconnect the first leg to the second leg at an interconnection point.

[0012] In one embodiment, the first foot extends from the first leg in the longitudinal direction, and the second foot extends from the second leg in the same longitudinal direction.

[0013] In one embodiment, the first foot includes a first upper section connected to a first lower section via a first fold, wherein a first portion of a first inner surface is associated with the first lower section of the first foot. In another embodiment, the second foot includes a second upper section connected to a second lower section via a second fold, wherein a first portion of a second inner surface is associated with the second lower section of the second foot.

[0014] In one embodiment, the first fold extends from the first flange and is substantially perpendicular to a first surface of the first flange. In another embodiment, the second fold extends from the second flange and is substantially perpendicular to a first surface of the second flange.

[0015] In one embodiment, the first upper segment of the first foot is oriented at a first tilt angle relative to the first lower segment of the first foot. In another embodiment, the second upper segment of the second foot is oriented at a second tilt angle relative to the second lower segment of the second foot.

[0016] In an embodiment, at least one of the first upper section of the first foot, the first lower section of the first foot, the second upper section of the second foot, and the second lower section of the second foot is generally planar.

[0017] In an embodiment, a first curved portion is formed between at least one of the first lower section and the first upper section of the first flange and the first foot; and / or a second curved portion is formed between at least one of the second lower section and the second upper section of the second flange and the second foot.

[0018] In one embodiment, the first opening of the first flange is a first elongated slot. In another embodiment, the second opening of the second flange is a second elongated slot.

[0019] In an embodiment, at least one of the first orifice and the second orifice is unthreaded.

[0020] In one embodiment, the first leg is a one-piece construction and is formed from a single piece of metal material. In another embodiment, the second leg is a one-piece construction and is formed from a single piece of metal material.

[0021] In one embodiment, the first hole extends through a first portion of the first inner surface, such that when the mounting bracket is secured to the trapezoidal rib, the shaft of the first fastener can extend through the first hole and the sidewall of the first rib to terminate in the hollow interior of the trapezoidal rib.

[0022] In one embodiment, the mounting bracket includes an angle bracket. The angle bracket includes a first arm having one or more of a first opening and a second opening. The angle bracket includes a second arm having an attachment aperture, wherein the shaft of a fastener may selectively extend through either the first opening or the second opening to interconnect the angle bracket to the first leg and the second leg.

[0023] In one embodiment, the shaft of the fastener defines a pivot axis, and the first and second legs are selectively rotatable about the pivot axis after the first leg is interconnected to the second leg via the shaft of the fastener.

[0024] In one embodiment, the first foot extends from the interconnection point between the first leg and the second leg along a first longitudinal direction. Optionally, the second foot extends from the interconnection point along the opposite second longitudinal direction.

[0025] In one embodiment, the mounting bracket includes at least one of a first washer and a second washer, the first washer selectively engaging a first portion of a first inner surface of a first foot such that the first washer covers a first hole, and the second washer selectively engaging a first portion of a second inner surface of a second foot such that the second washer covers a second hole.

[0026] A third aspect of this disclosure relates to a mounting member for interconnecting photovoltaic modules to a mounting bracket having an adjustable width, and the mounting bracket being secureable to a trapezoidal rib projecting from a building surface. The mounting member includes a body having a top end including a top surface. The mounting member includes a top aperture extending through the top surface. The mounting member includes a first PV platform extending outwardly from a first side of the mounting member, wherein the first PV platform includes a first upper surface adapted to selectively support a photovoltaic module. The mounting member includes an orifice extending through the first side of the mounting member, the orifice being configured to receive a fastener for interconnecting the mounting member to the mounting bracket.

[0027] In one embodiment, the mounting element includes a groove within a first upper surface of the first PV platform, wherein the groove is operable to receive a grounding insert having at least one recess that extends upward to engage the frame of the photovoltaic module when selectively supported.

[0028] In one embodiment, the grounding insert received by a groove on the first upper surface of the first PV platform includes one or more hooks to engage one or more ends of the first PV platform. In another embodiment, the grounding insert received by a groove on the second upper surface of the second PV platform includes one or more hooks to engage one or more ends of the second PV platform.

[0029] In one embodiment, the second PV platform extends outward from the second opposite side of the mounting member, wherein the second PV platform includes a second upper surface adapted to selectively support the second photovoltaic module.

[0030] In one embodiment, the mounting element further includes a groove within a second upper surface of the second PV platform, wherein the groove is operable to receive a grounding insert having at least one recess extending upward from the second upper surface to engage the frame of the second photovoltaic module in selective support.

[0031] In one embodiment, the first PV platform has a first length extending outward in a first direction from a first side of the mounting member. The second PV platform has a second length extending outward in a second direction from a second opposite side of the mounting member. The first length is longer than the second length.

[0032] In one embodiment, the first PV platform has a first stop near a first side of the mounting member, wherein the frame of the photovoltaic module contacts the first stop when selectively supported by the first PV platform, and wherein the first stop is configured to space the frame of the photovoltaic module from a central reference plane passing through the body by a first predetermined distance. The second PV platform has a second stop near a second opposite side of the mounting member, wherein the frame of the second photovoltaic module contacts the second stop when selectively supported by the second PV platform, and wherein the second stop is configured to space the frame of the second photovoltaic module from a central reference plane passing through the body by a second predetermined distance. The second predetermined distance is substantially equal to the first predetermined distance.

[0033] In this embodiment, a portion of the first upper surface of the first PV platform and a portion of the second upper surface of the second PV platform are each approximately planar. The first upper surface of the first PV platform and the second upper surface of the second PV platform are substantially coplanar.

[0034] In one embodiment, the cavity extends through the body between the first and second ends of the body.

[0035] In one embodiment, the top orifice extends through the top surface and into the cavity.

[0036] In one embodiment, the top orifice is threaded, wherein the internal thread of the top orifice has a pitch, and the depth of the top orifice is at least 2.5 times the pitch, such that the external thread of the clamp fastener engaging with the internal thread has at least 2.5 turns within the top orifice to prevent thread failure.

[0037] In one embodiment, the mounting member includes a mounting flange extending from a second opposite side of the mounting member, wherein the first PV platform is located vertically between the mounting flange and the top surface.

[0038] In one embodiment, the mounting flange is located vertically between the first PV platform and the orifice, such that when the mounting flange is interconnected with the mounting bracket, the contact between the mounting flange and the mounting bracket will prevent the mounting bracket from rotating unintentionally about the axis of the fastener.

[0039] A fourth aspect of this disclosure relates to a mounting system for engaging trapezoidal ribs projecting from a building surface and securing photovoltaic modules to the building surface. The mounting system includes a mounting bracket with an adjustable width. The mounting bracket includes a first leg and a first foot, the first leg having a first flange with a first orifice, and the first foot being connected to the first flange via a first bend, wherein a first portion of a first inner surface of the first foot faces a first rib sidewall of the trapezoidal rib when the mounting bracket is secured to the trapezoidal rib. The mounting bracket includes a second leg and a second foot, the second leg having a second flange with a second orifice, and the second foot being connected to the second flange via a second bend, wherein a first portion of a second inner surface of the second foot faces a second rib sidewall of the trapezoidal rib when the mounting bracket is secured to the trapezoidal rib. The mounting bracket includes a fastener comprising an axis operable to extend through the first and second orifices to interconnect the first leg to the second leg at an interconnection point. The mounting system includes a mounting member for interconnecting photovoltaic modules to the mounting bracket. The mounting member includes a body having a top end including a top surface. The mounting member includes a top orifice extending through the top surface. The mounting member includes a first PV platform extending outwardly from a first side of the mounting member, wherein the first PV platform includes a first upper surface adapted to selectively support a photovoltaic module. The mounting member includes an aperture extending through the first side of the mounting member, the aperture being configured as a shaft for receiving fasteners to interconnect the mounting member to a mounting bracket at interconnection points.

[0040] In one embodiment, the mounting system further includes a clamp adapted to selectively support a photovoltaic module, the clamp being attachable to the top of a mounting member. The clamp includes a first leg and a second leg, defining a cavity between the first and second legs, wherein a top surface has a width less than the width of the cavity defined between the first and second legs, and a portion of the body near the top has a second width greater than the width of the cavity, such that when the clamp is attached to the top of the mounting member, the first leg provides a frictional engagement with at least a first side of the mounting member.

[0041] In one embodiment, the mounting system further includes a second PV platform extending outward from a second opposite side of the mounting member, wherein the second PV platform includes a second upper surface adapted to selectively support the second photovoltaic module.

[0042] In one embodiment, the first foot includes a first outer surface, a first inner surface opposite to the first outer surface, and a first hole extending through the first inner surface and the first outer surface. Optionally, the second foot includes a second outer surface, a second inner surface opposite to the second outer surface, and a second hole extending through the second inner surface and the second outer surface.

[0043] In one embodiment, the mounting system includes a recess within a first upper surface of a first PV platform of the mounting member, wherein the recess is operable to receive a grounding insert having at least one recess extending upward from the first upper surface to engage the frame of the photovoltaic module in selective support.

[0044] In one embodiment, the mounting system includes a groove within a second upper surface of a second PV platform of the mounting member, wherein the groove is operable to receive a grounding insert having at least one recess extending upward from the second upper surface to engage the frame of the second photovoltaic module in selective support.

[0045] In one embodiment, the mounting system includes a clamp adapted to selectively support a photovoltaic module and a second photovoltaic module. The clamp is engageable to the top of a mounting member. The clamp includes a first leg and a second leg, defining a cavity between the first leg and the second leg. The top of the mounting member has a width smaller than the width of the cavity defined between the first leg and the second leg, such that when the clamp is engaged to the top of the mounting member, the first leg and the second leg provide a frictional engagement with at least a first side of the mounting member.

[0046] A fifth aspect of this disclosure relates to a mounting member for interconnecting photovoltaic modules to a mounting element that can be fixed to a building surface. The mounting member includes a body having a first side and a second side. The mounting member includes a cavity defined by the first side and the second side, the cavity being configured to receive a shaft of fasteners during interconnection between the mounting member and the mounting element. The mounting member includes a first aperture within the body, which is alignable with a second aperture in the mounting element during interconnection between the mounting member and the mounting element. The mounting member includes a first PV platform extending outwardly from the first side, wherein the first PV platform includes a first upper surface adapted to selectively support a photovoltaic module.

[0047] In one embodiment, the mounting member interconnects the second photovoltaic module to the mounting element. The mounting member also includes a second PV platform extending outward from a second side, wherein the second PV platform includes a second upper surface adapted to selectively support the second photovoltaic module.

[0048] The sixth aspect is to provide a mounting bracket whose width is adjustable to engage trapezoidal ribs of various sizes, comprising: (1) a first leg, comprising: (a) a first flange having a first orifice; and (b) a first foot connected to the first flange via a first bend, the first foot comprising a first outer surface oriented substantially perpendicular to the first flange, a first inner surface opposite to the first outer surface, and a first orifice extending through the first inner surface and the first outer surface, such that when the mounting bracket is fixed to the trapezoidal rib, a first portion of the first inner surface faces the first rib sidewall of the trapezoidal rib; (2) a second leg, the second leg comprising: (a) a second flange having a second orifice; and (b) a second foot connected to the second flange by a second bend, the second foot including a second outer surface oriented generally perpendicular to the second flange, a second inner surface opposite to the second outer surface, and a second orifice extending through the second inner surface and the second outer surface such that a first portion of the second inner surface faces the second rib sidewall of the trapezoidal rib when the mounting bracket is secured to the trapezoidal rib; and (3) a fastener including a shaft operable to extend through the first orifice and the second orifice to interconnect the first leg to the second leg.

[0049] In some embodiments, at least one of the first orifice and the second orifice is unthreaded.

[0050] In one or more embodiments, at least one of the first orifice and the second orifice is elongated to define a slot.

[0051] The mounting bracket of the sixth aspect may include one or more of those in the foregoing embodiments, and optionally, the first hole extends through a first portion of the first inner surface such that the shaft of the first fastener can extend through the first hole to engage the sidewall of the first rib, thereby securing the mounting bracket to the trapezoidal rib.

[0052] Optionally, when the mounting bracket is fixed to the trapezoidal rib, the first fastener may extend through the sidewall of the first rib to terminate inside the hollow interior of the trapezoidal rib.

[0053] Alternatively or concurrently, the mounting bracket of the sixth aspect may include one or more of those in the preceding embodiments, and optionally, the second hole extends through a first portion of the second inner surface such that a second fastener can extend through the second hole to engage the second rib sidewall, thereby securing the mounting bracket to the trapezoidal rib.

[0054] In some embodiments, when the mounting bracket is secured to the trapezoidal rib, the second fastener may extend through the sidewall of the second rib to terminate inside the hollow interior of the trapezoidal rib.

[0055] The mounting bracket in the sixth aspect may include one or more of the aforementioned embodiments, and optionally, one or more of the first hole and the second hole are threadless.

[0056] In at least one embodiment, one or more of the first fastener and the second fastener are threaded.

[0057] The mounting bracket of the sixth aspect may include one or more of the aforementioned embodiments, and optionally include a first washer that selectively engages with a first portion of the first inner surface of the first foot such that the first washer covers the first hole.

[0058] In one or more embodiments, a first portion of the first inner surface is generally planar.

[0059] Optionally, the first segment of the first outer surface is generally planar, and the first segment of the first outer surface is opposite to the first portion of the first inner surface.

[0060] Alternatively or in some embodiments, the first portion of the second inner surface is generally planar.

[0061] In at least one embodiment, the first segment of the second outer surface is generally planar, and the first segment of the second outer surface is opposite to the first portion of the second inner surface.

[0062] The mounting bracket of the sixth aspect may include one or more of the aforementioned embodiments, and in some embodiments, the first foot includes a first upper section connected to the first lower section via a first fold.

[0063] Optionally, the first upper section is oriented at an angle to the first lower section.

[0064] Alternatively or alternatively, a first portion of the first inner surface may be associated with a first lower section of the first foot.

[0065] In some embodiments, no orifice extends through the first upper section.

[0066] In at least one embodiment, the first inner surface includes a second portion that faces the upper surface of the upper wall of the trapezoidal rib when the mounting bracket is secured to the trapezoidal rib. In some embodiments, the second portion of the first inner surface is associated with a first upper section.

[0067] In one or more embodiments, the first fold extends substantially perpendicular to the first surface of the first flange.

[0068] The mounting bracket of the sixth aspect may include one or more of the aforementioned embodiments, and in some embodiments, the second foot includes a second upper section connected to the second lower section via a second fold.

[0069] Optionally, the second upper section is oriented at an angle to the second lower section.

[0070] Alternatively or alternatively, the first portion of the second inner surface may be associated with the second lower section of the second foot.

[0071] In some embodiments, no orifice extends through the second upper section.

[0072] In at least one embodiment, the second inner surface includes a second portion that faces the upper surface of the trapezoidal rib when the mounting bracket is secured to the trapezoidal rib.

[0073] In some embodiments, a second portion of the second inner surface is associated with a second upper section.

[0074] In one or more embodiments, the second fold extends substantially perpendicular to the first surface of the second flange.

[0075] The mounting bracket of the sixth aspect may include one or more of the aforementioned embodiments, and in some embodiments, the first leg is a one-piece construction and is formed from a single piece of metal material.

[0076] Alternatively or concurrently, in at least one embodiment, the second leg is a one-piece construction and is formed from a single piece of metal material.

[0077] In some embodiments, the first flange has a first thickness, and the first foot has a second thickness approximately equal to the first thickness.

[0078] Optionally, the second flange has a third thickness, and the second foot has a fourth thickness. In at least one embodiment, the third and fourth thicknesses are approximately equal to the first thickness.

[0079] In one or more embodiments, the first outer surface includes a first end and a second end, the first end being positioned close to the first bend and the first flange.

[0080] In some embodiments, the first flange includes a first surface facing away from the first bend and a second surface opposite to the first surface, the second surface facing the first bend. In these embodiments, the first surface defines a first reference plane that does not intersect with any portion of the first leg.

[0081] The mounting bracket of the sixth aspect may include one or more of those in the foregoing embodiments, and may optionally include a first protrusion that intersects with the first bend and extends from the first foot toward the second end of the first outer surface.

[0082] In some embodiments, the second surface of the first flange defines a second reference plane that intersects the first protrusion and the first foot.

[0083] The mounting bracket of the sixth aspect may include one or more of those in the foregoing embodiments, and may optionally include a pivot axis defined by the axis of the fastener, such that the first leg and the second leg may be selectively rotated about the pivot axis.

[0084] The mounting bracket in the sixth aspect may include one or more of the foregoing embodiments, and may optionally include attachments selectively fixed to the mounting bracket. In some embodiments, the attachment is a corner bracket. Alternatively, in other embodiments, the attachment is a photovoltaic (PV) mount.

[0085] The angle bracket may optionally include: (i) a first arm having one or more of a first opening and a second opening; and (ii) a second arm having an attachment orifice. The first and second openings are configured such that the shaft of a fastener may selectively extend through the first opening or the second opening to interconnect the angle bracket to the first leg and the second leg.

[0086] In at least one embodiment, the angle bracket can selectively rotate up to 360 degrees about the axis as the axis extends through the first opening of the angle bracket, without being obstructed by the first or second leg.

[0087] The mounting bracket in the sixth aspect may include one or more of those described in the foregoing embodiments, and may optionally include a mounting element for the photovoltaic module that can be selectively attached to the mounting bracket by means of fasteners.

[0088] In at least one embodiment, the mounting includes: (1) an orifice selectively aligned with a first orifice and a second orifice, the shaft of a fastener extending through the orifice and the first orifice and the second orifice to interconnect the mounting to a mounting bracket; (2) a top surface; (3) a top orifice extending through the top surface; and (4) a first photovoltaic (PV) platform extending from a first side of the mounting, wherein the first PV platform includes a first upper surface adapted to selectively support a photovoltaic module.

[0089] The mounting bracket may include one or more of the aforementioned embodiments, and optionally, the orifice is unthreaded.

[0090] In one or more embodiments, the orifice is elongated in the vertical dimension to define a slot.

[0091] The mounting bracket may include one or more of the aforementioned embodiments, and the top opening may optionally be threaded.

[0092] The mounting bracket of the sixth aspect may include any of the foregoing embodiments, and may optionally include a mounting flange extending from the second side of the mounting member.

[0093] In some embodiments, the first PV platform is located vertically between the mounting flange and the top surface.

[0094] Optionally, the opening is positioned vertically between the flange of the mounting member and the bottom end of the mounting member.

[0095] In at least one embodiment, the mounting flange extends away from the second side in a longitudinal dimension orthogonal to the vertical dimension.

[0096] In one or more embodiments, the mounting flange extends from a first end of the mounting member to a second end in a lateral dimension, the lateral dimension being orthogonal to the vertical and longitudinal dimensions.

[0097] The mounting bracket of the sixth aspect may optionally include one or more of those in the foregoing embodiments, and when the mounting member is interconnected with the mounting bracket and the second lateral first and second legs are in contact, the mounting member flange may selectively contact the side surfaces of the first and second flanges to prevent the mounting member from rotating about a pivot axis defined by the axis of the fastener.

[0098] In some embodiments, the mounting further includes: (a) a first end spaced apart from a second end in a lateral dimension orthogonal to the vertical dimension; and (b) a cavity extending from the first end through the mounting to the second end.

[0099] In at least one embodiment, the cavity is vertically positioned between the first PV platform and the top surface.

[0100] Optionally, the top orifice extends into the cavity.

[0101] The mounting bracket of the sixth aspect may include any one or more of the foregoing embodiments, and in some embodiments, the first upper surface of the first PV platform is generally planar.

[0102] In at least one embodiment, the first PV platform includes a first groove that is recessed downward in the vertical dimension relative to a first upper surface, and the first groove extends in the lateral dimension.

[0103] Optionally, the mounting bracket also includes a grounding insert configured to at least partially fit into the first recess such that when the grounding insert is engaged with the first PV platform, the upward surface of the grounding insert is substantially coplanar with the first upper surface of the first PV platform.

[0104] In some embodiments, the grounding insert includes: (a) a first hook for engaging a first end of a first PV platform; and (b) a second hook for engaging a second end of the first PV platform.

[0105] Optionally, the grounding insert also includes a recess extending from the upward surface, such that when the grounding insert is engaged with the first PV platform, the recess protrudes above the first upper surface of the first PV platform.

[0106] In one or more embodiments, the grounding insert is formed of a metal such as stainless steel.

[0107] The mounting bracket may include one or more of those described in the foregoing embodiments, and the first PV platform further includes a first stop extending vertically from the first upper surface.

[0108] In some embodiments, the first stop is positioned between the first groove and the first side of the mounting member.

[0109] Optionally, the first stop is configured to separate the frame of the photovoltaic module from a central reference plane that extends in both the vertical and horizontal dimensions and passes through the top opening by a predetermined distance.

[0110] The mounting bracket in the sixth aspect may include one or more of the aforementioned embodiments, and the mounting bracket may optionally further include a second PV platform extending from a second side of the mounting member, the second PV platform including a second upper surface adapted to selectively support the second photovoltaic module.

[0111] Optionally, the second PV platform is positioned vertically between the mounting flange and the top surface.

[0112] In at least one embodiment, the second upper surface of the second PV platform is generally planar.

[0113] In this embodiment, the second upper surface is substantially coplanar with the first upper surface of the first PV platform.

[0114] In one or more embodiments, the second PV platform includes a second groove that is recessed downward in the vertical dimension relative to the second upper surface, and the second groove extends in the lateral dimension.

[0115] Optionally, the second PV platform also includes a second stop extending vertically from the second upper surface.

[0116] In some embodiments, the second stop is positioned between the second groove and the second side of the mounting member.

[0117] The second stop can optionally be configured to space the frame of the second photovoltaic module from the central reference plane by a predetermined distance.

[0118] In one or more embodiments: (a) a first PV platform extends a first distance in the longitudinal dimension; and (b) a second PV platform extends a second distance in the longitudinal dimension, the second distance being smaller than the first distance.

[0119] The mounting bracket of the sixth aspect may include any one of the foregoing embodiments, and optionally, the mounting element is a one-piece construction and is formed from a single piece of metal material.

[0120] In some embodiments, the metallic material is aluminum.

[0121] A seventh aspect of this disclosure is to provide a mounting member for interconnecting a photovoltaic (PV) module to a mounting bracket that can be secured to a rib projecting from a building surface. The mounting member includes: (a) an orifice configured to receive a shaft of fasteners for interconnecting the mounting member to the mounting bracket; (b) a top surface; (c) a top aperture extending through the top surface; and (d) a first photovoltaic (PV) platform extending from a first side of the mounting member, the first PV platform including a first upper surface adapted to selectively support the photovoltaic module.

[0122] In some embodiments, the orifice is unthreaded.

[0123] Alternatively, the orifice is elongated in the vertical dimension to define the slot.

[0124] In at least one embodiment, the top opening is threaded.

[0125] In some embodiments, the internal thread of the top orifice has a pitch, and the depth of the top orifice is at least four times the pitch, such that the external thread of the clamp fastener engaging with the internal thread will have at least 2.5 turns in the top orifice, and in some cases at least four turns, to prevent thread failure.

[0126] The mounting element of the seventh aspect may include any one of the foregoing embodiments, and may optionally include a mounting flange extending from the second side of the mounting element.

[0127] In some embodiments, the first PV platform is positioned vertically between the mounting flange and the top surface.

[0128] Optionally, the opening is positioned vertically between the flange of the mounting member and the bottom end of the mounting member.

[0129] In one embodiment, the mounting flange extends away from the second side in a longitudinal dimension orthogonal to the vertical dimension.

[0130] In one or more embodiments, the mounting flange extends from a first end of the mounting member to a second end in a lateral dimension, the lateral dimension being orthogonal to the vertical and longitudinal dimensions.

[0131] Optionally, when the mounting component is interconnected with the mounting bracket and the second lateral mounting bracket is in use, the mounting component flange may selectively contact one or more portions of the mounting bracket to prevent the mounting component from rotating about a pivot axis defined by the axis of the fastener.

[0132] The mounting member of the seventh aspect may include any one or more of the foregoing embodiments, and optionally, the mounting member may further include: (a) a first end spaced apart from the second end in a lateral dimension orthogonal to the vertical dimension; and (b) a cavity extending from the first end through the mounting member to the second end.

[0133] In some embodiments, the cavity is located vertically between the first PV platform and the top surface.

[0134] In at least one embodiment, the top orifice extends into the cavity.

[0135] In some embodiments, the first upper surface of the first PV platform is generally planar.

[0136] Optionally, the first PV platform includes a first groove that is recessed downward in the vertical dimension relative to the first upper surface, and the first groove extends in the lateral dimension.

[0137] The mounting component of the seventh aspect may include one or more of those in the previous embodiments, and optionally, the mounting component may further include a grounding insert configured to at least partially fit into the first recess such that when the grounding insert is engaged with the first PV platform, the upward surface of the grounding insert is substantially coplanar with the first upper surface of the first PV platform.

[0138] Optionally, the grounding insert includes: (a) a first hook for engaging a first end of the first PV platform; and (b) a second hook for engaging a second end of the first PV platform.

[0139] In some embodiments, the grounding insert further includes a recess extending from the upward surface such that when the grounding insert is engaged with the first PV platform, the recess protrudes above the first upper surface of the first PV platform.

[0140] In at least one embodiment, the grounding insert is formed of a metal such as stainless steel.

[0141] In some embodiments, the first PV platform further includes a first stop extending vertically from the first upper surface.

[0142] Optionally, the first stop is positioned between the first groove and the first side of the mounting member.

[0143] In one or more embodiments, the first stop is configured to separate the frame of the photovoltaic module from a central reference plane that extends in both the vertical and horizontal dimensions and passes through the top opening by a predetermined distance.

[0144] The mounting component of the seventh aspect may include one or more of those in the previous embodiments, and may optionally include a second PV platform extending from a second side of the mounting component, the second PV platform including a second upper surface adapted to selectively support the second photovoltaic module.

[0145] In some embodiments, the second PV platform is positioned vertically between the mounting flange and the top surface.

[0146] In at least one embodiment, the second upper surface of the second PV platform is generally planar.

[0147] Optionally, the second upper surface is substantially coplanar with the first upper surface of the first PV platform.

[0148] In one or more embodiments, the second PV platform includes a second groove that is recessed downward in the vertical dimension relative to the second upper surface, and the second groove extends in the lateral dimension.

[0149] Optionally, the second PV platform also includes a second stop extending vertically from the second upper surface.

[0150] In one or more embodiments, the second stop is positioned longitudinally between the second groove and the second side of the mounting member.

[0151] In some embodiments, the second stop is configured to space the frame of the second photovoltaic module from the central reference plane by a predetermined distance.

[0152] In at least one embodiment, (a) a first PV platform extends a first distance in the longitudinal dimension; and (b) a second PV platform extends a second distance in the longitudinal dimension, the second distance being smaller than the first distance.

[0153] The mounting component of the seventh aspect may include any one or more of the foregoing embodiments, and optionally, the mounting component is a one-piece construction and is formed from a single piece of metal material.

[0154] In some embodiments, the metallic material is aluminum.

[0155] Alternatively, the mounting element is an extrusion.

[0156] One or more means for performing any one of the aspects described above or in the embodiments described herein.

[0157] Any aspect in combination with one or more other aspects.

[0158] Any one or more of the features disclosed herein.

[0159] Essentially any one or more of the features disclosed herein.

[0160] Combination of any one or more features substantially disclosed herein with any one or more other features substantially disclosed herein.

[0161] Any of these aspects / features / embodiments can be combined with any of one or more other aspects / features / embodiments.

[0162] Use of any one of the aspects or features disclosed herein.

[0163] The summary of this invention is neither intended nor should be construed as representing the entirety and scope of this disclosure. This disclosure is set forth in various degrees of detail in the summary, accompanying drawings, and detailed descriptions, and the inclusion or exclusion of elements, components, etc., in the summary is not intended to limit the scope of this disclosure. Other aspects of this disclosure will become clearer from the detailed descriptions, particularly in relation to the accompanying drawings. Figure 1 When it starts.

[0164] The phrases “at least one,” “one or more,” and “and / or” used in this article are open-ended terms that are both connected and separate in operation. For example, each of the terms “at least one of A, B, and C,” “at least one of A, B, or C,” “one or more of A, B, and C,” “one or more of A, B, or C,” and “A, B, and / or C” means A alone, B alone, C alone, A and B together, A and C together, B and C together, or A, B, and C together.

[0165] As used herein, the term “a” or “an” entity refers to one or more of the entity. Therefore, the terms “a” (or “an”), “one or more”, and “at least one” are used interchangeably herein.

[0166] Unless otherwise stated, all figures used in the specification and claims to indicate quantities, dimensions, conditions, ratios, ranges, etc., should be understood to be modified in all cases by the terms “about” or “approximately”. When used with numbers or ranges, the terms “about” and “approximately” indicate that the numbers or ranges may be “slightly above” or “slightly below” the endpoints, with the flexibility commonly recognized by those skilled in the art. Furthermore, unless otherwise specifically stated, the terms “about” and “approximately” may include exact endpoints. Therefore, unless otherwise stated, all figures used in the specification and claims to indicate quantities, dimensions, conditions, ratios, angles, ranges, etc., may be increased or decreased by about 5% to achieve satisfactory results. Additionally, where the meaning of the terms “about” or “approximately” as used herein is not obvious to those skilled in the art, the terms “about” and “approximately” should be interpreted as being within plus or minus 10% of the stated value.

[0167] Unless otherwise stated, the term "parallel" means two objects oriented at an angle between 0° and 5°. Similarly, unless otherwise stated, the terms "perpendicular" and "orthogonal" mean two objects oriented at an angle between 85° and 95°.

[0168] Unless otherwise stated, the term "substantially" means that a difference of 0% to 5% in the stated values ​​is acceptable.

[0169] Without departing from the invention, all ranges described herein may be reduced to any subrange or portion of that range, or to any value within that range. For example, the range “5 to 55” includes, but is not limited to, the subranges “5 to 20” and “17 to 54”.

[0170] The use of “including,” “comprising,” or “having,” and variations thereof in this document is intended to cover the items listed thereafter, their equivalents, and additional items. Therefore, the terms “including,” “comprising,” or “having,” and variations thereof are used interchangeably herein.

[0171] It should be understood that, pursuant to 35 U.S.SC, Section 112(f), the term “device” as used herein should be given its broadest possible interpretation. Therefore, claims containing the term “device” should cover all structures, materials, or actions set forth herein and all their equivalents. Furthermore, structures, materials, or actions and their equivalents should include all those described in the summary, description of the drawings, detailed description, abstract, and the claims themselves. Attached Figure Description

[0172] Embodiments of the disclosed system are illustrated in conjunction with the accompanying drawings, which are included and form part of this specification, and together with the general description of the disclosure given above and the detailed description of the drawings given below, serve to explain the principles of the disclosed system and apparatus.

[0173] Figure 1 This is a top, rear, and left perspective view of a mounting assembly including a mounting bracket according to an embodiment of the present disclosure, the mounting bracket being in a position for fixing to a first trapezoidal rib of a roof formed of a metal panel;

[0174] Figure 2 yes Figure 1 The front elevation view of the mounting bracket is shown, which is fixed to a second trapezoidal rib with different dimensions and geometry than the first trapezoidal rib. A clamping system for fixing to the mounting bracket is also shown, which clamps the two photovoltaic modules.

[0175] Figure 3 yes Figure 1 The top, front, and right perspective exploded views of the mounting components, and show the mounting bracket and optional associated hardware;

[0176] Figure 4 yes Figure 1 Top view of the mounting brackets and angle brackets;

[0177] Figure 5 yes Figure 1 Right elevation view of the mounting bracket and angle bracket;

[0178] Figure 6 It is in the first structure Figure 1 Front elevation view of the mounting bracket;

[0179] Figure 7 It is in the second structure Figure 6 Another front elevation view of the mounting bracket;

[0180] Figure 8A yes Figure 1 Top, front, and right perspective views of the left leg of the mounting bracket;

[0181] Figure 8B yes Figure 8A Front elevation view of the left leg;

[0182] Figure 8C yes Figure 8A Rear elevation view of the left leg;

[0183] Figure 8D yes Figure 8A A top-down view of the left leg;

[0184] Figure 8E yes Figure 8A A top-down view of the left leg;

[0185] Figure 8F yes Figure 8A Left elevation view of the left leg;

[0186] Figure 8G yes Figure 8A Right elevation view of the left leg;

[0187] Figure 9A yes Figure 1 Top, front, and right perspective views of the right leg of the mounting bracket;

[0188] Figure 9B yes Figure 9A Front elevation view of the right leg;

[0189] Figure 9C yes Figure 9A Rear elevation view of the right leg;

[0190] Figure 9D yes Figure 9A Top view of the right leg;

[0191] Figure 9E yes Figure 9A A top-down view of the right leg;

[0192] Figure 9F yes Figure 9A Left elevation view of the right leg;

[0193] Figure 9G yes Figure 9A Right elevation view of the right leg;

[0194] Figure 10A This is a top, front, and right perspective view of a mounting assembly including a mounting bracket according to an embodiment of the present disclosure;

[0195] Figure 10B yes Figure 10A Top, front, and right perspective views of the first and second legs of the mounting bracket;

[0196] Figure 11A This is a top, front, and left perspective view of a mounting assembly that includes another mounting bracket of this disclosure;

[0197] Figure 11B yes Figure 11A Top, front, and left perspective views of the first and second legs of the mounting bracket;

[0198] Figure 12A This is a left elevation view of a mounting assembly in use according to an embodiment of the present disclosure, the mounting assembly including mounting members interconnected to a mounting bracket, and showing a clamping system for securing to the mounting bracket, the clamping system clamping a single photovoltaic module;

[0199] Figure 12B yes Figure 12A Left front perspective view of the installation components;

[0200] Figure 13A yes Figure 12A Top, rear, and right perspective views of the mounting components;

[0201] Figure 13B yes Figure 13A Left elevation view of the mounting component;

[0202] Figure 13C yes Figure 13A Left cross-sectional view of the mounting component;

[0203] Figure 13D yes Figure 13A Front elevation view of the mounting component;

[0204] Figure 13E yes Figure 13A Rear elevation view of the installed components;

[0205] Figure 13F yes Figure 13A Top view of the mounting components;

[0206] Figure 14A This is a left elevation view of a mounting assembly in use according to an embodiment of the present disclosure, the mounting assembly including mounting members interconnected to a mounting bracket, and showing a clamping system for securing to the mounting bracket, the clamping system clamping two photovoltaic modules;

[0207] Figure 14B yes Figure 14A Left front perspective view of the installation components;

[0208] Figure 15A yes Figure 14A Top, rear, and right perspective views of the mounting components;

[0209] Figure 15B yes Figure 15A Left elevation view of the mounting component;

[0210] Figure 15C yes Figure 15A Left cross-sectional view of the mounting component;

[0211] Figure 15D yes Figure 15A Front elevation view of the mounting component;

[0212] Figure 15E yes Figure 15A Rear elevation view of the installed components;

[0213] Figure 15F yes Figure 15A Top view of the mounting components;

[0214] Figure 16A This is a perspective view of a grounding insert according to an embodiment of the present disclosure;

[0215] Figure 16B yes Figure 16A Front elevation view of the grounding insert;

[0216] Figure 16C yes Figure 16A Top plan view of the grounding insert; and

[0217] Figure 16D yes Figure 16A Left elevation view of the grounding insert.

[0218] The accompanying drawings are not necessarily (but may) drawn to scale. In particular, Figures 6 to 7 , Figures 8A to 8G , Figures 9A to 9G Figure 10 to Figure 10B , Figures 11A to 11B , Figures 13B to 13F , Figures 15B to 15F and Figures 16A to 16D Draw to scale.

[0219] In some cases, details that are not necessary for understanding this disclosure or that make other details difficult to perceive may have been omitted. It should be understood, of course, that this disclosure is not necessarily limited to the embodiments shown herein. As will be understood, other embodiments are possible, using one or more features set forth above or described below, individually or in combination. For example, it is conceivable that various features and means shown and / or described with respect to one embodiment may be combined with or substituted for features or means of other embodiments, regardless of whether such combinations or substitutions are specifically shown or described herein.

[0220] The following is a list of components according to various embodiments of this disclosure, and is illustrated in the accompanying drawings:

[0221] Digital components

[0222] 2. Roof

[0223] 4. Metal panel

[0224] 6 Trapezoidal ribs

[0225] 8. Panel base

[0226] 10 Sidewalls

[0227] 12 upper wall

[0228] 14 Hollow interior

[0229] 18 Install Components

[0230] 20 Mounting brackets

[0231] 22 Base

[0232] 24 First Leg

[0233] 26 First flange

[0234] 28 First flange fold

[0235] 30 First Orifice

[0236] 32 Slot length

[0237] 34 First surface of the first flange

[0238] 36 First Reference Plane

[0239] 38 The first side of the first reference plane

[0240] 40 The second side of the first reference plane

[0241] 42 The second surface of the first flange

[0242] 44 Second Reference Plane

[0243] 46 First Bend

[0244] 48 First kick

[0245] 50 First foot section

[0246] 52 The free end of the first foot

[0247] 54 First outer surface

[0248] 56 First inner surface

[0249] 58 First lower section

[0250] 60 First portion of the first inner surface

[0251] 62 The first segment of the first outer surface

[0252] 64 First Fold

[0253] 66 First Upper Section

[0254] 68 The second part of the first inner surface

[0255] 70 The second section of the first outer surface

[0256] 72. Length of the first foot

[0257] 74 Second leg

[0258] 76 Second flange

[0259] 78 Second flange fold

[0260] 80 Second Orifice

[0261] 84 First surface of the second flange

[0262] 86 Third Reference Plane

[0263] 88 The first side of the third reference plane

[0264] 90 The second side of the third reference plane

[0265] 92 Second surface of the second flange

[0266] 94 Fourth Reference Plane

[0267] 96 Second bend

[0268] 98 Second kick

[0269] 100 Second foot section

[0270] 102 The free end of the second foot

[0271] 104 Second outer surface

[0272] 106 Second Inner Surface

[0273] 108 Second Lower Section

[0274] 110 The first part of the second inner surface

[0275] 112 The first segment of the second outer surface

[0276] 114 Second Fold

[0277] 116 Second Upper Section

[0278] 118 The second part of the second inner surface

[0279] 120 Second section of the second outer surface

[0280] 122 Length of the second leg

[0281] 130 Passing through the openings of the first and second feet

[0282] 132 Washer

[0283] 134 Protrusions in the first and second bends

[0284] 136 Fold between flange and foot

[0285] 138 First Construction

[0286] 140 First width of the first structure

[0287] 142 Second Construction

[0288] 144 The second width of the second construction

[0289] 150 Fasteners

[0290] 152 heads

[0291] 154 Square neck

[0292] 156 shafts

[0293] 158 Pivot axis

[0294] 160 thread

[0295] 162 nuts

[0296] 164 Fasteners

[0297] 168 Accessories

[0298] 170 angle bracket

[0299] 172 First Arm

[0300] 174 First Opening

[0301] 176 Second opening

[0302] 178 Second Arm

[0303] 180 Attachment port

[0304] 186 Fixture System

[0305] 188 Mounting Panel

[0306] 190. Support or pedestal

[0307] 192 PV clamps

[0308] 193 Clamp Legs

[0309] 194 Clamping Fasteners

[0310] 195 External threads of clamp fasteners

[0311] 196 photovoltaic modules

[0312] 197 cavities

[0313] Framework of 198 PV modules

[0314] 199 Top Wall

[0315] 200 installation parts

[0316] 202 Main Body

[0317] 204 First End

[0318] 206 Second End

[0319] 208 Top

[0320] 210 Top Wall

[0321] 212 Thickness of the top wall

[0322] 214 Top surface

[0323] 216 Top opening

[0324] 218 Internal Thread

[0325] 220mm borehole axis

[0326] 222 Center Reference Plane

[0327] f cavity

[0328] 225 protrusion

[0329] 226 Maximum width at the top

[0330] 228 Slope

[0331] 230 Minimum width at the top

[0332] 232 First Side

[0333] 234 Second side

[0334] 236 The second side planar surface

[0335] 238 bottom

[0336] 240 First PV Platform

[0337] 242 First upper surface

[0338] 244 First Platform Reference Plane

[0339] 246 First Groove

[0340] 248 First stop

[0341] 250 First outer surface of the first stop

[0342] 252. Predetermined distance between the stop and the center reference plane

[0343] 254 First length of the first photovoltaic (PV) platform

[0344] 260 Mounting flange

[0345] 262 Lower surface of flange

[0346] 264 Flange length

[0347] 270 Second PV Platform

[0348] 272 Second upper surface

[0349] 274 Second Platform Reference Plane

[0350] 276 Second Groove

[0351] 278 Second stop

[0352] 280 Second outer surface of the second stop

[0353] 282 The second length of the second PV platform

[0354] 290 orifices

[0355] 300 Grounding Insert

[0356] 302 Insert Body

[0357] 304 upward surface

[0358] 306 First End

[0359] 308 First Hook

[0360] 310 Second End

[0361] 312 Second hook

[0362] 314 Dent

[0363] X Horizontal dimension

[0364] Y vertical dimension

[0365] Z longitudinal dimension

[0366] Z1 Longitudinal dimension

[0367] Z2 longitudinal dimension Detailed Implementation

[0368] Now refer to Figure 1 Figure 9 generally illustrates a mounting assembly 18A including a mounting bracket 20A according to an embodiment of the present disclosure. Figure 1-2 As roughly shown, the mounting bracket 20A can be adjusted to accommodate trapezoidal ribs 6A and 6B of different sizes. The trapezoidal ribs 6 extend from the metal panels 4A and 4B that define the roof 2 of the building.

[0369] The trapezoidal rib typically includes a first sidewall 10A and a second sidewall 10B extending from the base portion 8 of the metal panel. The sidewalls 10 extend inwardly from the base portion to the upper wall 12 of the respective trapezoidal rib. The upper wall 12 is positioned at a predetermined height above the base portion 8, wherein the base portion 8 is spaced a predetermined width apart. The sidewalls are oriented at an oblique angle to the upper wall and the base portion, and the sidewalls 10 are not parallel to each other. The upper wall 12 and the two sidewalls 10A, 10B together define the hollow interior 14 of the trapezoidal rib 6. It should be understood that the dimensions of the trapezoidal rib 6 are not limited to those specified herein without departing from the scope of this disclosure. Figure 1 and Figure 2 The dimensions shown are as indicated, and the upper wall and the two side walls 10A, 10B may have any dimensional relationship with each other (e.g., resulting in any predetermined height above the base portion 8 and / or a predetermined width between the base portions 8).

[0370] Mounting bracket 20A typically includes a base 22A, which includes a first leg 24A and a second leg 74A. In some embodiments, the first and second legs are interconnected by a fastener 150, which includes, but is not limited to, a bolt. In a non-limiting example, the fastener 150 may be a carriage bolt, which includes a head 152, a square neck 154 extending from the head, and a shaft 156 having external threads 160 extending from the square neck. The shaft 156 defines a pivot axis 158 about which one or more of the first leg 24A and the second leg 74A can be rotated until a nut 162 is tightened onto the fastener 150.

[0371] The first leg 24A is adjustable relative to the fastener 150 and the second leg 74A until the nut 162 is tightened onto the threaded shaft 156 of the fastener 150. Therefore, as... Figure 1-2 As roughly shown in 6-7, the mounting bracket 20A can be adjusted to a first configuration 138 having a first width 140 to engage the first trapezoidal rib 6A of the first metal panel 4A. Figure 6 As generally shown, in some embodiments, the first width 140 is measured between the first fold portion 64A of the first leg 24A and the second fold portion 114A of the second leg 74A. In a first configuration, the first width 140 may be approximately equal to the upper wall 12A of the first trapezoidal rib 6A, such as... Figure 1 As shown in the figure.

[0372] Alternatively, the mounting bracket 20A can also be adjusted to a second configuration 142 having a second width 144 of a different size than the first width. In this way, in the second configuration 142, the mounting bracket 20A can engage a second trapezoidal rib 6B with different dimensions and geometries (e.g., different predetermined heights and / or predetermined widths). See again Figure 7 In some embodiments, the second width 144 may also be measured between the first fold 64A and the second fold 114A. In the second configuration, the second width 144 may be approximately equal to the upper wall 12B of the second trapezoidal rib 6B, such as... Figure 2 As shown in the figure.

[0373] It should be noted that the clamping system 186A (e.g., having a mounting panel 188, a support column 190, a clamp 192A, and a clamp fastener 194) and the PV module 196 with the frame 198 are not limited to... Figure 2 The orientation shown. For example, clamping system 186A and PV module 196 can be rotated to be oriented alternatively in the longitudinal dimension Z, rather than in the orientation shown. Figure 2The PV module 196 is oriented in the lateral dimension X, while the frame 198 of the PV module 196 is oriented in the longitudinal dimension Z, similar to legs 26A and 76A (e.g., similar to PV module 196, where the frame 198 is mounted in mounting members 200A and 200B, as described further in detail herein). In this respect, Figure 2 This should not be construed as restrictive, but merely as an explanation of this disclosure.

[0374] Now refer to Figures 8A to 8G The first leg 24A typically includes a first flange 26A that connects to (or extends from) the first foot 48A at the first bend 46A. Similarly, as Figures 9A to 9G As generally shown, the second leg 74A includes a second flange 76A that connects to (or extends from) the second foot 98A at the second bend 96A.

[0375] It is worth noting that, compared to some prior art mounting brackets, the first leg 24 and the second leg 74 can each be formed from a single piece of metal. More specifically, in embodiments, the first and second legs are formed by cutting, forming, stamping, and / or bending a continuous sheet of metal from a roll. In some embodiments, the continuous sheet has a thickness of approximately 0.125 inches (3.175 mm). The roll is unrolled, and the continuous sheet is fed into a forming apparatus. As the sheet moves through the forming apparatus in an indexing manner, tooling operations progressively cut, stamp, form, and / or shape the first and second legs from the sheet. In this respect, the first leg 24 and the second leg 74 are each a single piece of construction and are not welded assemblies formed from multiple parts or components.

[0376] It should be noted that forming legs 24, 74 in this manner is more efficient and cheaper than forming prior art mounting brackets by cutting and welding together multiple metal parts. For example, each of the left leg 24 and right leg 74 in all embodiments of this disclosure can be formed in less time than it would take to form legs of a prior art mounting bracket of approximately the same size that requires welding the parts together. Furthermore, the first leg 24 and second leg 74 of this disclosure require less equipment and less labor to produce compared to legs of prior art mounting brackets. Finally, forming equipment that uses cutting, stamping, forming, and otherwise forming the left and right legs 24, 74 can utilize metal panel material more efficiently and reduce metal waste compared to methods used to form legs of prior art mounting brackets of similar size and construction. In some exemplary configurations, it is conceivable that forming legs 24, 74 as described throughout this disclosure results in a 40% to 60% reduction in manufacturing costs and an increase in manufacturing efficiency compared to mounting brackets formed by cutting and welding together multiple metal parts.

[0377] The first flange 26A and the second flange 76A are generally planar. In some embodiments, the first flange and the second flange each have a thickness of about 0.125 inches (3.175 mm) as measured in the longitudinal dimension Z.

[0378] The first flange has a first surface 34A that is opposite to the first bend 46A in the longitudinal dimension Z. The second surface 42A, opposite to the first surface 34A, faces the longitudinal dimension Z and is toward the first bend 46A.

[0379] The first flange 26A has a first aperture 30A, and the second flange 76A has a second aperture 80A. The dimensions of the first aperture 30A and the second aperture 80A are designed to receive the threaded shaft 156 of the fastener 150.

[0380] In some embodiments, one or more of the first aperture 30A and the second aperture 80A are unthreaded. Figure 8B As generally shown, the first flange 26A may optionally include two or more generally circular first apertures 30A'. Additionally or alternatively, the second flange 76A may optionally include two or more second apertures 80A', which are generally circular, such as... Figure 9B As shown. In some embodiments, the circular openings 30A' and 80A' may be formed to correspond to the dimensions of a specific trapezoidal rib 6.

[0381] Alternatively, one or more of the first aperture 30A and the second aperture 80A may be elongated to define a slot. In some embodiments, the slots of the first and second apertures have a slot length 32 between about 1.5 inches and 2 inches or about 1.8 inches.

[0382] It is conceivable that the first flange 26A may optionally include a combination of an elongated slot orifice 30A and a generally circular orifice 30A', and / or the second flange 76A may optionally include a combination of an elongated slot orifice 80A and a generally circular orifice 80A', without departing from the scope of this disclosure. For example, the combination of orifices 30A, 30A on the first flange 26A and / or the combination of orifices 80A, 80A on the second flange 76A may be aligned along the axial center on the transverse dimension X, and / or may be offset on the vertical dimension Y.

[0383] In at least one embodiment, no protrusion, projection, or extension is formed on the first surface 34A of the first flange 26A. Therefore, in this embodiment, the first surface 34A defines a first reference plane 36A that does not intersect any portion of the first leg 24A, such as... Figure 8D As shown in the general diagram. The first reference plane 36A extends along the mutually orthogonal horizontal dimension X and vertical dimension Y.

[0384] The second surface 42A of the first foot 48A, away from the first flange 26A, extends to the free end 52A of the first foot 48A. Therefore, the free end 52A is spaced from the first flange 26A by a predetermined length 72A of the first foot 48A. In some embodiments, the length of the first foot 48A is between about 1 inch and 4 inches. Optionally, the length 72A is between about 1.8 inches and about 2.1 inches, or about 1.9 inches. The length 72A is measured along the longitudinal dimension Z, which is orthogonal to the lateral dimension X and the vertical dimension Y.

[0385] The first foot 48A typically includes a first outer surface 54A, a first inner surface 56A, a first lower section 58A, and a first upper section 66A connected to the first lower section 58A via a first fold 64A. In at least one embodiment, the first fold 64A extends substantially perpendicular to the second surface 42A of the first flange 26A.

[0386] It should be noted that the first bend 46A may be formed between the first flange 26A, the first lower section 58A of the first foot 48A, and the first upper section 66A of the first foot 48A. In this respect, the transition between the first flange 26A and the first foot 26A can be considered seamless and without welding or joints.

[0387] like Figure 8B As generally shown, the first fold 64A forms an angle of a predetermined size between a first portion 60A and a second portion 68A of the first inner surface 56A. In some embodiments, the size of this angle is between about 120° and 150°, or about 135°. Generally, the first upper section 66A should be understood to be oriented at an angle to the first lower section 58A. The angle between the first portion 60A and the second portion 68A of the first inner surface 56A facilitates engagement between the first foot 48A and the trapezoidal ribs 6 of different geometries and sizes.

[0388] A hole 130 is formed through the first lower section 58A. The hole extends through a first segment 62A of the first outer surface 54A and through a first portion 60A of the first inner surface 56A.

[0389] In some embodiments, the hole is unthreaded. The hole 130 is sized to receive a shaft of fastener 164 (e.g., a metal panel screw, rivet, etc.), which can extend through the hole and be driven through the first sidewall 10A and into the hollow interior 14 of the trapezoidal rib 6 to secure the first leg 24A to the metal panel 4 (e.g., as shown in the figure). Figure 2 (As shown).

[0390] In some embodiments, the first foot 48A includes only one hole 130. Alternatively, in some embodiments, the first lower section has two or more holes 130.

[0391] When the first leg 24A is fastened to the trapezoidal rib 6, a first portion 60A of the first inner surface 56A is oriented to face the first sidewall 10A of the trapezoidal rib 6. In some embodiments, when the fastener 164 is tightened to the appropriate extent, at least some of the first portions of the first inner surface may contact the trapezoidal rib.

[0392] When the first leg 24A is fastened to the trapezoidal rib 6, the first upper section 66A of the first foot 48A is positioned above the upper wall 12. Therefore, the second portion 68A of the first inner surface 56A is oriented toward (and can at least partially contact) the upper wall 12A.

[0393] It is worth noting that in at least some embodiments, no hole or opening is formed through the first upper section 66A. Therefore, in at least one embodiment, the second portion 68A of the first inner surface 76A and the second segment 70A of the first outer surface 54A (both associated with the first upper section 66A of the first foot) do not have holes or openings.

[0394] In some embodiments, the first bend 46A between the first flange 26A and the first leg 48A is not linear. Alternatively, the first bend 46A may include a protrusion 134 and one or more folds 136. In some embodiments, the first leg 24A includes two folds 136.

[0395] The protrusion 134 and the fold 136 (when present) are formed during the flat forming of the metal panel, and the first bend 46A is formed by tooling operations of the forming apparatus as described above. The protrusion and the fold cause the metal material to shift during metal forming to form the first flange and the first foot. Forming the protrusion and the fold (or multiple folds) to address the shifted metal material is advantageous because it avoids the operation of cutting the flat metal sheet, thereby saving manufacturing steps, associated time, and waste of metal material.

[0396] refer to Figure 8D The protrusion 134 and one or more folds 136 extend from the second surface 42A of the first flange 26A. Therefore, a second reference plane 44A, defined by the planar portion of the second surface 42A, intersects the protrusion and the folds. The second reference plane 44A extends in the lateral dimension X and the vertical dimension Y. Furthermore, in at least some embodiments, the second surface 42A can be described as planar except where the protrusion and the folds intersect with the first flange 26A.

[0397] In at least one embodiment, the first foot 48A has a thickness of approximately 0.125 inches (3.175 mm). Therefore, in at least some embodiments, the thickness of the first foot 48A is approximately equal to the thickness of the first flange 26A, since they are formed from the same wound sheet.

[0398] In some embodiments, the second leg 74A has many features that are the same as or similar to those of the first leg 24A. In some embodiments, but not necessarily in every embodiment of this disclosure, the second leg 74A is a mirror image of the first leg 24A.

[0399] The second flange 76A has a first surface 84A that is away from the second curved portion 96A in the longitudinal dimension Z. The second surface 92A, opposite to the first surface 84A, faces the second curved portion 96A in the longitudinal dimension Z.

[0400] In at least one embodiment, no protrusion, projection, or extension is formed on the first surface 84A of the second flange 76A. Therefore, in this embodiment, the first surface 84A defines a third reference plane 86A that does not intersect any portion of the second leg 74A, such as... Figure 9D As shown in the figure.

[0401] The second surface 92A of the second foot 98A extends away from the second flange 76A to the free end 102A of the second foot 98A. Therefore, the free end 102A is spaced apart from the second flange 76A by a predetermined length 122A of the second foot 98A. In at least one embodiment, the length 122A of the second foot 98A is approximately equal to the length 72A of the first foot 48A. In some embodiments, the length of the second foot is between about 1 inch and 4 inches. Optionally, the length 122A is about 1.9 inches.

[0402] The second foot 98A typically includes a second outer surface 104A, a second inner surface 106A, a second lower section 108A, and a second upper section 116A connected to the second lower section 108A via a second fold 114A. In at least one embodiment, the second fold 114A extends substantially perpendicular to the second surface 92A of the second flange 76A.

[0403] It should be noted that the second bend 96A may be formed between the second flange 76A, the second lower section 108A of the second foot 98A, and the second upper section 106A of the second foot 98A. In this respect, the transition between the second flange 76A and the second foot 76A can be considered seamless and without welding or joints.

[0404] like Figure 9BAs generally shown, the second fold 114A forms an angle of a predetermined size between the first portion 110A of the second inner surface 106A and the second portion 118A of the second inner surface 106A. In some embodiments, the size of this angle is between about 120° and 150°, or about 135°. Generally, the second upper section 116A should be understood to be oriented at an inclined angle to the second lower section 108A.

[0405] A hole 130 is formed through the second lower section 108A. The hole extends through a first segment 112A of the second outer surface 104A and through a first portion 110A of the second inner surface 106A.

[0406] In some embodiments, the hole is unthreaded. The hole 130 is sized to receive the shaft of the fastener 164, such that it can extend through the hole and be driven through the second sidewall 10B and into the hollow interior 14 of the trapezoidal rib 6 to fasten the second leg 74A to the metal panel 4 (e.g., as shown in the image). Figure 2 (As shown).

[0407] In some embodiments, the second foot 98A includes only one hole 130. Alternatively, in some embodiments, the second lower section has two or more holes 130.

[0408] When the second leg 74A is fastened to the trapezoidal rib 6, the first portion 110A of the second inner surface 106A is oriented to face the second sidewall 10B of the trapezoidal rib 6. In some embodiments, when the fastener 164 is tightened to the appropriate extent, at least some of the first portion of the second inner surface 106A may contact the trapezoidal rib 6.

[0409] When the second leg 74A is fastened to the trapezoidal rib 6, the second upper section 116A of the second leg is positioned above the upper wall 12. Therefore, the second portion 118A of the second inner surface 106A is oriented toward (and can at least partially contact) the upper wall 12.

[0410] It is worth noting that in at least some embodiments, no hole or opening is formed through the second upper section 116A. Therefore, in at least one embodiment, the second portion 118A of the second inner surface 106A and the second segment 120A of the second outer surface 104A (both associated with the second upper section 116A of the second foot) do not have holes or openings.

[0411] In some embodiments, the second bend 96A between the second flange 76A and the second leg 98A is not linear. Alternatively or additionally, the second bend 96A may include a protrusion 134 similar to that of the second leg and one or more folds 136. In some embodiments, the second leg 74A includes two folds 136. The protrusion 134 and folds 136 (when present) are the same as (or similar to) the protrusion and folds of the first leg and are formed in a similar manner by a forming device.

[0412] refer to Figure 9D The protrusion 134 and one or more folds 136 extend from the second surface 92A of the second flange 76A. Therefore, the fourth reference plane 94A, defined by the planar portion of the second surface 92A, will intersect the protrusion and the folds. Furthermore, in at least some embodiments, the second surface 92A may be described as planar, except where the protrusion and the folds intersect with the second flange 76A.

[0413] In one or more embodiments, the second foot 98A has a thickness of approximately 0.125 inches (3.175 mm). Therefore, in at least some embodiments, the thickness of the second foot 98A is approximately equal to the thickness of the second flange 76A, since they are formed from the same wound sheet. Furthermore, in some embodiments, the first flange 26A, the second flange 76A, the first foot 48A, and the second foot 98A each have approximately equal thicknesses.

[0414] Now for reference Figure 3 In some embodiments, a washer 132 of any suitable type (e.g., an EPDM washer) is disposed between one or more of the feet 48A, 98A and the corresponding sidewalls 10A, 10B of the trapezoidal rib 6. Optionally, the washer may be applied to a first inner surface 56A of the first foot and a second inner surface 106A of the second foot. Each washer 132 may be positioned to cover one or more holes 130 of the foot. Thus, the shaft of the fastener 164 may extend through the holes 130 in the feet 48A, 98A and through the washer 132 before extending through one of the sidewalls of the trapezoidal rib.

[0415] refer to Figure 3 The illustration generally shows an embodiment in which an attachment 168 can be selectively interconnected to a mounting bracket 20 using fasteners 150. In some non-limiting examples, the attachment 168 is a corner bracket 170. In other non-limiting examples, the attachment 168 may be a photovoltaic mount 200, as described in further detail herein.

[0416] exist Figure 3In this embodiment, attachment 168 is an example of angle bracket 170. Angle bracket 170 can be of any suitable size and geometry. In some embodiments, angle bracket 170 includes a first arm 172 and a second arm 178. In at least one embodiment, the first arm 172 is substantially orthogonal to the second arm 178.

[0417] The first arm 172 may include a first opening 174 and a second opening 176, each sized to receive a shaft 156 of a fastener 150. The second arm 178 includes an attachment aperture 180. In some embodiments, the attachment aperture 180 may be elongated to define a slot. In other embodiments, the second arm 178 may optionally include at least one generally circular attachment aperture 180'.

[0418] It is conceivable that, without departing from the scope of this disclosure, the second arm 178 may optionally include a combination of an elongated slot orifice 180 and a generally circular orifice 180'. For example, the combination of orifices 180, 180' on the second arm 178 may be aligned along the axis center on the longitudinal dimension Z, and / or may be offset on the transverse dimension X.

[0419] In some embodiments, the first opening 174 is elongated in the vertical dimension Y to define a slot. The slot may optionally have a length between about 1.1 inches and about 1.5 inches, or about 1.3 inches.

[0420] Optionally, the first opening 174 and the second opening 176 have a width, measured in the lateral dimension X, between approximately 0.29 inches and approximately 0.37 inches, or approximately 0.33 inches. The widths of the first and second openings are chosen to receive the square neck 154 of the fastener 150. This helps prevent rotation of the fastener 150 relative to the angle bracket 170 and the mounting bracket 20A. Therefore, the nut 162 can be tightened onto the threaded shaft 156 with only one wrench, thus saving time during the assembly and installation of the mounting bracket 20A onto the roof 2.

[0421] An embodiment of a fastener 164 that can be inserted into the corresponding hole 130 to secure feet 48A, 98A to trapezoidal rib 6 is also included. Figure 3 The fastener 164 is generally shown in the diagram. It can be a threaded fastener, such as a metal panel screw with a threaded shaft. However, any suitable fastener known to those skilled in the art can be used with the mounting brackets of this disclosure. Therefore, in some embodiments, one or more of the fasteners 164 can be rivets.

[0422] like Figure 1As generally shown in Figure 9, the first foot 48A and the second foot 98A are oriented in the longitudinal dimension Z such that the hole 130 is located on the same side of the mounting assembly 18A. It is conceivable that this facilitates providing access on the same side of the mounting assembly 18A and provides a mounting assembly 18A with a smaller footprint. Additionally, it should be noted that in one example, this is possible where the trapezoidal rib 6 on the roof 2 has mounting tracks (e.g., photovoltaic tracks) to facilitate positioning (and access) of the first foot 48A and the second foot 98A without obstruction by the tracks.

[0423] Refer again Figure 2 When the mounting bracket 20 is secured to the roof, the first arm 172 of the corner bracket 170 is oriented along the vertical dimension Y, and the second arm 178 extends along the longitudinal dimension Z away from the first surface 34 of the first flange 26A. The clamping system 186A can be used to secure one or more photovoltaic modules 196 to the mounting bracket. However, it is conceivable that, without departing from the scope of this disclosure, the corner bracket 170, together with the first arm 172 and / or the second arm 178, may be oriented in any dimension, depending on the nature or construction of the mounting assembly 18A (e.g., regarding a preference for a smaller footprint and greater accessibility of the aperture 130, etc.).

[0424] Various clamping systems 186A can be fixed to the angle bracket 170. A suitable clamping system 186A includes a mounting panel 188 fixed to the angle bracket 170 via a support post 190. PV clamps 192 are adjustablely fixed to the support post 190 via clamp fasteners 194. In this way, the frame of one or two photovoltaic (PV) modules 196 (in...) Figure 2 (Partially shown in vertical cross-section) can be fixed between clamp 192 and mounting panel 188.

[0425] The angle bracket 170 is arranged on the first side 38 of the first reference plane 36 and the first foot 48A and the second foot 98A are arranged on the second side 40 of the first reference plane (e.g.) Figures 4 to 5 (As shown) This is beneficial during the installation of the photovoltaic module 196 on the roof 2. More specifically, and again referring to Figures 1 to 2 When the photovoltaic module 196 is secured to the angle bracket 170 via the clamping system 186A, the frame of the photovoltaic module 196 will not cover or obstruct access to the holes 130 in the feet 48A, 98A. This is advantageous because it makes it easier to tighten the fasteners 164 required to secure the legs 24A, 74A to the trapezoidal ribs 6.

[0426] In contrast, some existing mounting brackets have holes for fasteners on both the first and second sides of the vertical extension, such that at least one hole on each side of the trapezoidal rib is positioned below the frame of the photovoltaic module. Therefore, access to the holes for fasteners is limited, and an extension of the drill bit and actuator is required to tighten the fasteners, making installation more difficult. Furthermore, as will be understood, bringing additional tools to the work site (or even up to the roof) is cumbersome, time-consuming, and inefficient.

[0427] It is also advantageous to form legs 24A and 74A with feet 48A and 98A only on the second side 40 of the first reference plane, because when feet 48A and 98A are optionally formed with two holes 130 for fasteners 164 respectively, the two fasteners 164 for each foot 48A and 98A will resist pull-out in the vertical dimension Y. For example, when the photovoltaic module 196 is fixed to such Figure 1 When the angle bracket 170 is positioned as shown, the second arm 178 of the angle bracket is pushed downward in the Y dimension, and the first foot 48A and the second foot 98A attempt to move away from the trapezoidal rib and pull upward in the Y dimension. In some embodiments, such as Figure 1 As shown, each foot 48A, 98A has two holes 130 for fastener 164. Therefore, all four fasteners 164 can resist upward movement of the feet in the Y dimension.

[0428] In contrast, some prior art mounting brackets have holes for fasteners on both the first and second sides of the vertical extension. This typically results in one fastener for each of the two feet being located below the photovoltaic module (i.e., both fasteners securing the prior art mounting bracket are positioned below the PV module), and one fastener for each of the two feet not being located below the PV module (i.e., only two fasteners of the prior art mounting bracket are not positioned below the PV module). The applicant has found that the fasteners not positioned below the PV module are more effective in resisting upward movement (or lifting) of the mounting bracket feet.

[0429] Another unexpected benefit of the arrangement of the feet 48A and 98A of legs 24A and 74A is that, through testing, feet 48A and 98A can be formed to have a shorter length than the feet of prior art mounting brackets of similar size, while still providing sufficient strength. For example, in some embodiments of this disclosure, feet 48A and 98A have a length of approximately 2 inches or less. In contrast, a prior art mounting bracket has feet with a total length of four inches (each foot extending two inches on each side away from the vertical support). However, during testing, the lifting force resisted by the mounting bracket 20A of this disclosure is approximately equal to the lifting force resisted by a prior art mounting bracket. Therefore, in some embodiments, the mounting bracket 20A of this disclosure can be formed with less metal material and still be substantially as effective as a prior art mounting bracket formed with more metal material.

[0430] exist Figures 10A-10B The image shows including Figure 1 A variant of the mounting bracket 20A of the -9 type, the mounting assembly 18B, is identified as the mounting bracket 20B. Figure 1 -9 and Figures 10A-10B Corresponding components between embodiments are identified by the same reference numerals. Those corresponding components that differ in at least some respects may be further identified by the letter "B" following the reference numerals. Unless otherwise stated herein, the discussion of the details (including its various features) of the mounting bracket 20A remains equally applicable. Figures 10A-10B Mounting bracket 20B.

[0431] Mounting bracket 20B typically includes a first leg 24B and a second leg 74B, each leg being formed from a single piece of metal material. The first leg 24B and the second leg 74B can be formed by combining mounting bracket 20A with a forming device as described herein.

[0432] The first leg 24B includes a first flange 26B connected to the first foot 48B via a first bend 46B. Similarly, the second leg 74B includes a second flange 76B connected to the second foot 98B via a second bend 96B. It is noteworthy that in some embodiments, the first and second bends are substantially linear. In this respect, the first leg 24B and the second leg 74B are each a single piece and not a welded assembly formed from multiple parts or components.

[0433] One difference between mounting bracket 20B and mounting bracket 20A is that the upper sections 66B and 116B of the feet 48B and 98B are separated from the corresponding first flange 26B and second flange 76B. In some embodiments, the first fold 64B and the second fold 114B of the feet 48B and 98B do not extend to the flanges. The material between the flanges 26B and 76B and the upper sections 66B and 116B (and optionally the folds 64B and 114B) is removed by a forming device.

[0434] Another difference is that the first foot 48B extends from the first flange 26B along the first lateral dimension Z1, and the second foot 98B extends from the second foot 98B along the second lateral dimension Z2, which is opposite to the first lateral dimension. Therefore, the feet extend from the flanges in opposite directions. Furthermore, the angle bracket 170 is positioned between the free ends 52B and 102B of the feet 48B and 98B.

[0435] exist Figure 11A-11B The image shows including Figure 1 Another mounting component 18B of the mounting brackets 20A and 20B of -9 and 10A-10B (which is identified as mounting bracket 20C) is also present. Figure 1-10B and Figure 11A-11B Corresponding components between embodiments are identified by the same reference numerals. Those corresponding components that differ in at least some respects may be further identified by the letter "C" following the reference numerals. Unless otherwise stated herein, the discussion of the details (including their various features) of mounting brackets 20A and 20B remains equally applicable. Figure 11A-11B Mounting bracket 20C.

[0436] Mounting bracket 20C typically comprises a first leg 24C and a second leg 74C, each leg being formed from a single piece of metal material. The first leg 24C and the second leg 74C can be formed in conjunction with mounting bracket 20A using forming equipment as described herein. In this respect, the first leg 24C and the second leg 74C are each a single piece of construction and are not welded assemblies formed from multiple parts or components.

[0437] The first leg 24C includes a first flange 26C formed by folding metal material at a first flange fold 28C. The second flange 76C is also formed by folding metal material at a second flange fold 78C. Therefore, the thickness of the first and second flanges is approximately twice the thickness of the metal material used to form the mounting bracket. In some embodiments, the thickness of the first and second flanges is approximately 0.25 inches.

[0438] The first leg 24C includes a first foot 48C formed by two first foot segments 50C having a first lower section 58C, wherein each first foot segment 50C is connected to the first flange 26C via a first bend 46C. Similarly, the second leg 74C includes a second foot 98C, which includes two second foot segments 100C having a second lower section 108C, wherein each second foot segment 100C is connected to the second flange 76C via a second bend 96C.

[0439] It is worth noting that the feet 48C and 98C of the mounting bracket 20C extend from the first flange 26C and the second flange 76C on both the first longitudinal dimension Z1 and the second longitudinal dimension Z2. More specifically, two of the foot segments 50C and 100C extend on the first longitudinal dimension Z1, and two other foot segments 50C and 100C extend on the second longitudinal dimension Z2.

[0440] The thickness of feet 48C and 98C is approximately equal to the thickness of the metal material forming the legs. Therefore, in some embodiments, feet 48C and 98C have a thickness of approximately 0.125 inches.

[0441] Similar to mounting bracket 20B, in some embodiments of mounting bracket 20C, the upper sections 66C, 116C of feet 48C, 98C are separated from the corresponding first flange 26C and second flange 76C. In some embodiments, the first fold 64C and the second fold 114C of feet 48C, 98C do not extend to the flanges. Material between flanges 26C, 76C and upper sections 66C, 116C (and optionally folds 64C, 114C) is removed by forming equipment.

[0442] Now for reference Figure 12A-12B This generally illustrates a mounting assembly 18D according to another embodiment of the present disclosure. Mounting assembly 18D typically includes another embodiment of a clamping system 186B and an attachment 168B, which is selectively attached to the mounting bracket 20 of all embodiments of the present disclosure. Attachment 168B is mounting member 200A. Although mounting member 200A is... Figure 12A-12B The mounting bracket 200A is shown as interconnected to the mounting bracket 20A, but alternatively, the mounting bracket 200A may also be interconnected to the mounting brackets 20B and 20C of this disclosure.

[0443] Mounting component 200A (combined) Figures 13A-13F as well as Figure 12A-12B (In more detail) It typically includes a body 202A, which is configured to support a photovoltaic module 196 of the photovoltaic array. Therefore, the mounting component 200A can be referred to as an "edge mounting component".

[0444] The main body 202A is also configured to be connected (or engaged by) the photovoltaic (PV) clamp 192B of the clamping system 186B, the PV clamp 192B being configured to engage only one PV module 196 supported by the mounting member 200A. The PV clamp 192B may be referred to as an “edge clamp”.

[0445] The main body 202A typically includes a first end 204A opposite to the second end 206A in the lateral dimension X. The main body 202A has a top end 208, the top end 208 has a top wall 210, and the top wall 210 has a top surface 214. The first side 232 of the main body 202A is spaced apart from the second side 234A in the longitudinal dimension Z.

[0446] Mounting member 200A includes a bottom end 238 opposite to the top end 208. A notch 290 extends from a first side 232 to a second side 234A through the lower portion of the body 202A near the bottom end 238. The notch 290 is adapted to receive the shaft 156 of the fastener 150 for interconnecting the mounting member 20 to the mounting bracket 20 of all embodiments of this disclosure.

[0447] Optionally, the orifice 290 is elongated in the vertical dimension Y to form a slot. Forming the orifice 290 as a slot facilitates upward or downward adjustment of the mounting member 200 in the vertical dimension Y during the assembly of the mounting assembly 18B. Adjusting the vertical position of the mounting member 200A is advantageous, for example, to adjust the lowest point on the roof 2. In this way, adjacent PV modules 196 can be arranged such that their upper surfaces are substantially coplanar, regardless of any unevenness or inconsistency in the roof 2.

[0448] A top hole 216 extends through the top surface 214 into the top wall 210. Mounting member 200A may optionally include two or more top holes 216 in the top wall 210.

[0449] In some embodiments, the top hole 216 is threaded. In these embodiments, the orifice axis 220 is concentrically aligned with the threaded top hole 216.

[0450] In at least one embodiment, the thread of the top hole 216 is adapted to engage a clamp fastener 194 having a shaft with a diameter of 8 mm and a pitch of 1.25 mm. It should be understood that shafts with this geometry are commonly referred to as M8-1.25.

[0451] Optionally, the orifice axis 220 extends in the vertical dimension Y. In at least some embodiments, the orifice axis 220 extends in both the lateral dimension X and the vertical dimension Y and intersects the central reference plane 222 of the body 202A. The body 202A is asymmetrical with respect to the central reference plane 222.

[0452] Alternatively, in other embodiments, the top aperture is unthreaded. Additionally or alternatively, the top aperture 216 may be elongated in the lateral dimension X to define a slot.

[0453] In at least one embodiment, cavity 224 extends through body 202A from first end 204A to second end 206A. Optionally, top hole 216 extends into cavity 224.

[0454] When present, cavity 224 advantageously reduces the amount of material used to form mount 200A. For example, in some embodiments, cavity 224 reduces the volume of mount 200A by approximately 0.48 inches. 3 (approximately 7.87cm) 3 This significantly reduces the volume of material used to form the mounting 200A. In some embodiments, the cavity 224 reduces the volume of the mounting 200A by approximately 20% compared to a mounting of similar size and geometry formed without the cavity.

[0455] In some embodiments, and now refer to Figure 13B-13C Cavity 224 may optionally include one or more protrusions 225. For example, one or more protrusions 225 may aid in the routing of electrical wires, lines, or other cable wiring. As another example, one or more protrusions 225 may provide increased strength when the mounting member 200A is extruded along the lateral dimension X. In some non-limiting configurations, one or more protrusions 225 may extend from a first end 204A to a second end 206A, similar to cavity 224. It should be noted that protrusions 225 may or may not be shown to scale, but may be shown, for example, only for clarity. Figure 13B-13C Enlarged to medium size.

[0456] The top wall 210 has a thickness 212 measured in the vertical dimension between the top surface 214 and the upper surface of the cavity 224. In some embodiments, the thickness 212 of the top wall is selected such that (when the top hole 216 is threaded) there is a sufficient number of turns of the internal thread 218 within the top hole 216 (e.g., at least 2.5 turns, and in some cases, at least 4 turns) to provide a secure engagement with the external thread 195 of the clamping fastener 194 of the clamping system 186B. Optionally, the thickness 212 is between about 0.25 inches and about 0.35 inches (6.35 mm and 8.89 mm), or about 0.30 inches (7.62 mm).

[0457] Near the top surface, the top end 208 has a maximum width 226 between approximately 0.5 and 0.7 inches (12.7 mm and 17.78 mm) measured in the longitudinal dimension Z. In some embodiments, the maximum width 226 is approximately 0.6 inches (15.24 mm).

[0458] Optionally, the mounting component 200A may include one or more ramps 228, such as Figure 13B As generally shown. In some embodiments, the first ramp 228A is positioned between the top surface 214 and the first side 232. Alternatively, the second ramp 228B may be positioned between the top surface 214 and the second side 234A.

[0459] When present, one or more ramps 228 advantageously reduce the maximum width 226 of the top edge, measured at the top surface 214, to a minimum width. In this way, one or more ramps 228 further reduce the volume of material required to form the mounting 200A.

[0460] The minimum width 230 is less than the maximum width 226. In some embodiments, the minimum width 230 is between approximately 0.35 inches and 0.55 inches (8.89 mm and 13.97 mm). Alternatively, in other embodiments, the minimum width is approximately 0.45 inches (11.43 mm).

[0461] One or more ramps 228 (when present) allow the legs 193 of the clamp 192B to be mounted on the top end 208, wherein after the legs 193 are engaged by one or more ramps 228 (when present), a cavity 197 defined between the legs 193 and the top wall 199 of the clamp 192B at least partially receives the top wall 210 and the top surface 214 of the top end 208. More specifically, in at least some embodiments, the maximum width 226 of the top end 210 is greater than the minimum internal width between the ends of the legs 193 of the clamp 192B. Thus, one or more ramps 228 are used to extend the legs 193 and increase the minimum internal width between the ends of the legs 193.

[0462] When assembling the clamp 192B onto the mount 200A prior to engaging the PV module 196, the increased width 226 relative to the minimum internal width between the ends of the legs 193 of the clamp 192B is further advantageous. The maximum width 226 is greater than the minimum internal width between the legs 193, which provides frictional engagement between the legs 193 and the first and second sides near the top end 208. This frictional engagement between the legs and the first and second sides of the mount prevents the clamp 192B from accidentally or unintentionally moving downwards during the assembly of the clamping system 186B. More specifically, the friction between the legs 193 and the mount 200A prevents the clamp from falling or sliding downwards toward the top surface 214 on the mount 200A. This facilitates providing space for the PV module 196 to be received on the first PV platform 240, such as... Figure 12A As shown in the general diagram. Conversely, if the clamp 192A falls downwards before the PV module is positioned between the clamp 192A and the first PV platform 240, the clamp 192A will block the PV module and prevent the PV module from being properly engaged by the clamp 192A.

[0463] In contrast, other known clamping systems include biasing elements, such as springs, to keep the clamp away from the mounting surface during assembly. For example, several clamping systems are shown in U.S. Patent US11,296,648 (the entire contents of which are incorporated herein by reference), and these systems include springs to push the clamp away from the base of the clamping system. Using separate components, such as springs, disadvantageously increases the time required to assemble the clamping system. Furthermore, the need for separate components for the clamping system means that additional components must be ordered during installation, kept available, and brought to the work site, increasing costs and reducing efficiency.

[0464] Mounting component 200A also includes a first PV platform 240 extending from the first side 232. The first PV platform 240 typically includes a first upper surface 242 adapted to support the photovoltaic module 196.

[0465] In at least some embodiments, the first upper surface 242 is generally planar. Therefore, the first upper surface 242 can be described as defining a first platform reference plane 244, such as... Figure 13C As roughly shown in the diagram. The first platform reference plane extends along the lateral dimension X and the longitudinal dimension Z.

[0466] The first PV platform 240 optionally includes a first recess 246. The first recess 246 is adapted to receive a grounding insert 300, which is typically located in... Figure 12A-12B As shown in 16A-16D.

[0467] The first recess 246 is recessed relative to the first upper surface 242. For example, in some embodiments, the first recess is recessed below the first upper surface 242 by approximately 0.02 inches (approximately 0.50 mm) in the vertical dimension Y. The depth of the first recess 246 advantageously ensures that the upward surface 304 of the grounding insert 300 is substantially coplanar with the first platform reference plane 244.

[0468] Arranging the upward surface of the grounding insert 300 substantially coplanar with the first platform reference plane 244 is advantageous when the photovoltaic module 196 is located on the first PV platform 240, to prevent the frame 198 of the PV module 196 from becoming trapped on the grounding insert 300. As those skilled in the art will understand, if the frame 198 of the PV module 196 becomes trapped on the grounding insert 300, the grounding insert 300 can be removed from the mounting member 200A, preventing electrical connection between the PV module 196 and the clamping system 186, as well as potential interference with the ground fault current path.

[0469] The first groove 246 may optionally extend from a first end 204A of the mounting member 200A to a second end 206A. When present, the first groove 246 typically extends in the lateral dimension X.

[0470] In some embodiments, the first PV platform 240 may further include a first stop 248. The first stop extends from the first PV platform 240 in the direction of the top end 208 in a vertical dimension Y. Therefore, the first platform reference plane 244 intersects with the first stop 248.

[0471] A first stop 248 is provided to restrict movement of the PV module frame 198 toward the central reference plane 222. The first outer surface 250 of the first stop 248 is positioned at a predetermined distance 252 from the central reference plane 222 (e.g., ...). Figure 13C (Approximately as shown in the diagram). Therefore, the first stop 248 separates the frame 198 from the central reference plane 222 by a predetermined distance, as shown in the diagram. Figure 12A As shown in general. In addition, in some cases, the first stop 248 is aligned with a portion of the leg 193 of the clamp 192B (e.g., the uppermost portion of the leg 19 near the upper wall of the clamp 192B).

[0472] In at least some embodiments, the predetermined distance 252 is approximately equal to the maximum distance between the outer surface of the leg 193 of the PV clamp 192B and the central reference plane 222. This is advantageous during installation to ensure that the PV module is secured to both the PV clamp 192B and the first PV platform 240.

[0473] In some embodiments, the predetermined distance 252 is between about 0.50 inches and about 0.60 inches (12.7 mm and 15.24 mm). Optionally, the predetermined distance 252 is about 0.56 inches (14.22 mm).

[0474] Optionally, the first outer surface 250 of the first stop 248 defines the inner surface of the first groove 246. Therefore, the first stop 248 can be described as being between the first groove and the first side 232 of the body 202A.

[0475] The first PV platform 240 has a first length 254 extending in the longitudinal dimension Z and measured from the central reference plane 222. In some embodiments, the first length 254 is between about 1.5 inches and about 1.9 inches (3.81 cm and 4.83 cm), or about 1.7 inches (4.32 cm).

[0476] Mounting member 200A also includes mounting flange 260 extending from a second side 234A in the longitudinal dimension Z. In some embodiments, mounting flange 260 extends from a first end to a second end of mounting member 200A.

[0477] When the mounting member 200A is interconnected to the mounting bracket 20 of any embodiment of this disclosure, wherein the second side 234A faces the mounting bracket 20, the mounting member flange 260 is at the first flange 26 and the second flange 76 (e.g., flanges 26A and 76A of the mounting bracket 20A, such as...). Figure 12A and Figure 12B It extends above the edge (as shown in the general diagram). Specifically, as... Figure 12B As shown, when assembling mounting assembly 18B, mounting flange 260 may contact one (or both) of the first flange 26A and the second flange 76A. More specifically, lower surface 262 may contact at least one of flanges 26A and 76A. In some embodiments, lower surface 262 is generally planar.

[0478] The contact between mounting flange 260 and one or more of flanges 26, 76 advantageously prevents accidental and unintentional rotation of mounting member 200A about a pivot axis 158 defined by the axis 156 of the fasteners 150 that interconnect mounting member 200A to mounting bracket 20A. Furthermore, when mounting bracket 20 is attached to a generally symmetrical building surface (such as roof 2), the contact between mounting flange 260 and flanges 26, 76 will align the first upper surface 242 of the first PV platform 240 generally parallel to the plane defined by the upper wall 12 of the trapezoidal ribs 6 of the building surface. In this way, the PV module 196 supported by the array of mounting assemblies 18B will also be generally parallel to the plane defined by the upper wall 12.

[0479] Because the mounting flange 260 only needs to contact flanges 26, 76, in at least some embodiments, the flange length 264 of the mounting flange must be approximately equal to the thickness of flanges 26, 76. Therefore, in at least one embodiment, the flange length 264 is less than approximately 0.50 inches (12.7 mm) as measured in longitudinal dimension Z from the surface of the second side 234A. In some embodiments, the flange length is less than approximately 0.4 inches (10.2 mm). Forming a mounting flange 260 with a length greater than that required to contact flanges 26, 76 would waste material used to form the mounting 200A.

[0480] In some embodiments, a portion of the second side 234A (e.g., surface 236) is generally planar between the mounting flange 260 and the bottom end 238 of the body 202A. This planar surface 236 facilitates ensuring that when the nut 162 is tightened onto the fastener 150, the second side 234A can be pulled closer to the first flange 26 and the second flange 76, allowing the mounting flange to extend above the upper surface of the flange.

[0481] In at least one embodiment, the second side 234A has no protrusion or projection between the lower surface 262 of the flange and the bottom end 238 of the mounting member 200A. Therefore, the planar surface 236 can extend continuously from the lower surface 262 to the bottom end 238.

[0482] The mounting flange 260 is optionally positioned in the vertical dimension Y between the first PV platform 240 and the orifice 290. Furthermore, the first PV platform is positioned in the vertical dimension between the mounting flange and the top surface 214.

[0483] Mounting member 200A can be formed from any suitable material. In some embodiments, mounting member 200A is formed from metal. Optionally, the metal is an aluminum alloy.

[0484] In at least one embodiment, the mounting member 200A is formed by an extrusion process. For example, in some embodiments, the mounting member does not have any bent or folded material.

[0485] Furthermore, in some embodiments, the mounting element 200A is formed from a single piece of material. For example, in one embodiment, the mounting element 200A does not have any material parts joined together by welding or fasteners. Thus, the mounting element can be described as having a single body 202A, or having a single (or monolithic) construction.

[0486] Now for reference Figures 14A-14B The image generally illustrates a mounting assembly 18E according to another embodiment of the present disclosure. Mounting assembly 18E typically includes a clamping system 186C and another embodiment of an attachment 168C, which is selectively attached to the mounting bracket 20 of all embodiments of the present disclosure. Attachment 168C is a mounting member 200B according to another embodiment. Although mounting member 200B is... Figures 14A to 14B The mounting element 200B is shown as interconnected to mounting bracket 20A, but alternatively, mounting element 200B may also be interconnected to mounting brackets of any embodiment, including mounting brackets 20B and 20C of this disclosure.

[0487] Combination Figures 12A to 12B and Figures 13A to 13F The described mounting parts 200A and 200B (in combination) Figures 14A to 14B and Figures 15A to 15F Corresponding parts between the described parts are identified by the same reference numerals. Those corresponding parts of the mounting 200B that differ in at least some respects may be further identified by the letter "B" following the reference numerals. Unless otherwise stated herein, the discussion of the details of the mounting 200A (including its various features) remains equally applicable. Figures 14A to 14B and Figures 15A to 15F Mounting component 200B.

[0488] Mounting component 200B typically includes a main body 202B, which is configured to support two photovoltaic modules 196 of the photovoltaic array, with the mounting component 200B positioned between the two photovoltaic modules 196. Therefore, mounting component 200B can be referred to as an "intermediate mounting component".

[0489] The main body 202B is also configured to be connected (or fixed) to the photovoltaic (PV) clamp 192A of the clamping system 186C. The PV clamp 192A is configured to engage two PV modules 196 supported by the mounting member 200B. Therefore, the PV clamp 192A can be referred to as an "intermediate clamp".

[0490] Body 202B typically includes the same (or similar) top hole 216, first PV platform 240, and mounting flange 260 as body 202A. Body 202B is asymmetrical with respect to central reference plane 222.

[0491] Optionally, body 202B may also include a cavity 224 (e.g., having an optional protrusion 225) that is the same as or similar to the cavity in body 202A. The cavity (when present) has the same benefits as in body 202A and advantageously reduces the volume of body 202B. For example, without the cavity, the volume of body 202B would be approximately 2.71 in. 3 (approximately 44.41cm) 3 ), and the cavity has a size of approximately 0.48 inches. 3 (approximately 7.87cm) 3 The volume of the body 202B with the cavity is only about 2.23 inches. 3 (approximately 36.54cm) 3 The cavity reduces the volume of the body 202B by approximately 18%. This significantly saves the volume of material required to form the mounting 200B and results in significant cost savings. It should be noted that the optional protrusion 225 may or may not be shown to scale, but may be shown, for example, only for clarity. Figure 15B-15C Enlarged to medium size.

[0492] It is worth noting that the main body 202B includes a second PV platform 270 extending from the second side 234B. The second PV platform 270 typically includes a second upper surface 272 adapted to support the second photovoltaic module 196.

[0493] In at least some embodiments, the second upper surface 272 is generally planar. Therefore, the second upper surface 272 can be described as defining a second platform reference plane 274. The second platform reference plane 274 extends in the lateral dimension X and the longitudinal dimension Z.

[0494] In at least some embodiments, the second PV platform 270 is positioned substantially opposite to the first PV platform 240 relative to the central reference plane 222. Therefore, in at least one embodiment, the first and second platform reference planes 244, 274 are coplanar.

[0495] The second PV platform 270 optionally includes a second recess 276. The second recess 276 is adapted to receive a grounding insert 300, for example... Figure 14A and 16A This is roughly shown in -16D.

[0496] The second groove 276 is recessed relative to the second upper surface 272. For example, in some embodiments, the second groove 276 is recessed below the second upper surface 272 by approximately 0.02 inches (approximately 0.50 mm) as measured in the vertical dimension Y. The depth of the second groove 276 advantageously ensures that the upward surface 304 of the grounding insert 300 is substantially coplanar with the second platform reference plane 274, and thus provides similar benefits to the first groove 246.

[0497] The second groove 276 may optionally extend from the first end 204B of the mounting member 200B to the second end 206B. When present, the second groove 276 typically extends in the lateral dimension X.

[0498] In some embodiments, the second PV platform 270 may further include a second stop 278. The second stop 278 is provided to restrict movement of the frame 198 of the second PV module toward the central reference plane 222. The second stop 278 extends from the second PV platform 270 in the vertical dimension Y in the direction of the top end 208. Therefore, the second platform reference plane 274 intersects with the second stop 278.

[0499] The second outer surface 280 of the second stop is positioned at a predetermined distance from the central reference plane 222. Therefore, the second stop 278 spaces the frame 198 from the central reference plane 222 by a predetermined distance. The second stop 278 may optionally be positioned at the same distance from the central reference plane 222 as the first stop 248. More specifically, in some embodiments, the first and second stops are arranged substantially symmetrically with respect to the central reference plane 222. Furthermore, in some cases, the first stop 248 and the second stop 278 are aligned with a portion of the leg 193 of the clamp 192A, such as... Figure 14A As shown in general (e.g., the uppermost part of the upper wall of leg 193 near clamp 192A).

[0500] In at least some embodiments, a predetermined distance is provided between the second outer surface 280 and the central reference plane 222, approximately equal to the maximum distance between the outer surface of the leg 193 of the PV clamp 192A and the central reference plane 222. This is advantageous during installation to ensure that the PV module 196 is secured to both the PV clamp and the second PV platform 270.

[0501] In some embodiments, the predetermined distance between the second outer surface 280 and the central reference plane 222 is between about 0.50 inches and about 0.60 inches (12.7 mm and 15.24 mm). Optionally, the predetermined distance is about 0.56 inches (14.22 mm).

[0502] Optionally, the second outer surface 280 of the second stop 278 defines the inner surface of the second groove 276. Therefore, the second stop 278 can be described as being between the second groove 276 and the second side 234B of the body 202AB.

[0503] The second PV platform 270 has a second length 282 extending in the longitudinal dimension Z and measured from the central reference plane 222. In at least one embodiment, the second length 282 is less than the first length 254. Forming the second PV platform 270 with a second length 282 shorter than the first length 254 of the first PV platform 240 is advantageous for saving material used in forming the mounting member 200B. The second PV platform 270 can be formed with a second length shorter than the first length.

[0504] In some non-restrictive examples of the installation process, Figures 12A to 12B Mounting component 200A or Figures 14A to 14B Mounting member 200B and mounting member 200B can be mounted on roof 2. Next, a first side of the frame of the first PV module 196 is typically positioned on the PV platform 240 of mounting member 200A or mounting member 200B. Furthermore, a second side of the frame 198 of the first PV module 196 is lowered onto the second PV platform 270 of mounting member 200B. It should be noted that the first PV platform 240 is designed with a relatively long first length to aid engagement when the installer lifts the first PV module 196 and pushes it toward the first stop 248. Once the first side of the frame 198 of the first PV module 196 is positioned on the first PV platform 240 of mounting member 200A or bracket 200B, the second side of the frame 198 is easily positioned on the second PV platform 270 simply by lowering the second side of the frame 198 while the first PV module 196 is supported by mounting member 200A or bracket 200B. Therefore, the second PV platform 270 does not need to have a second length equal to the first length. It should be noted that the installation process can continue, with the additional PV module 196 installed on the mounting pieces 200A and 200B in a similar manner.

[0505] It should be understood that Figure 12A A first side of the first frame 198 of the first PV module 196 is shown (e.g., positioned on the PV platform 240 and insert 300, and prior to being pushed upward against the optional stop 248 of the mount 200A). Additionally... Figure 14A The first frame 198 of the first PV module 196 is shown mounted on a second side (e.g., positioned on the PV platform 270 and insert 300, with the first frame pushed upward against an optional stop 278 of the mount 200B), and pre-mounted on a first side of the second frame 198 of the second PV module 196 (e.g., on the PV platform 240 of the mount 200B).

[0506] Typically, one option in the installation process is to "push the column upwards," or to position the mounting components 200A and 200B so that the PV module 196 is installed from a low point on the roof 2 to a high point on the roof 2. In this regard, installers can utilize gravity during the installation process to help hold the PV module 196 on the first PV platform 240 while simultaneously installing the PV module 196 on the second PV platform 270.

[0507] In some embodiments, the second length 282 is between about 1 inch and about 1.41 inches (2.54 cm and 3.58 cm). Optionally, the second length 282 is about 1.21 inches (3.07 cm).

[0508] Mounting member 200B can be formed from any suitable material. In some embodiments, mounting member 200B is formed from metal. Optionally, the metal is an aluminum alloy.

[0509] In at least one embodiment, the mounting member 200B is formed by an extrusion process. For example, in some embodiments, the mounting member does not have any bent or folded material.

[0510] Furthermore, in some embodiments, the mounting member 200B is formed from a single piece of material. For example, in one embodiment, the mounting member 200B does not have any material parts joined together by welding or fasteners. Thus, the mounting member can be described as having a single body 202B, or having a single (or monolithic) construction.

[0511] In some embodiments, mounting members 200A and 200B are manufactured by an extrusion process, followed by drilling of hole 216 and punching of hole 290. It should be noted that cavity 224 is hollow to reduce weight and provide space for drilling when hole 216 is formed, without requiring blind holes during the drilling process.

[0512] Now for reference Figures 16A-16DThe image generally illustrates a grounding insert 300 according to an embodiment of the present disclosure. The grounding insert 300 is configured to engage recesses 246, 276 of the PV platforms 240, 270 of the mounting members 200A, 200B to engage and ground the frame 198 of the PV module 196 mounted on the PV platforms 240, 270 to the mounting members 200A, 200B.

[0513] The grounding insert typically includes an insert body 302 having a first end 306 spaced apart from the second end 310. The first end includes a first hook 308 to engage an edge of the PV platforms 240, 270 (e.g., at one end 204, 206 of the PV platforms 240, 270). The second end includes a second hook 312 to engage opposite edges of the PV platforms (e.g., at opposite ends 204, 206 of the PV platforms 240, 270). In this way, the grounding insert 300 can be engaged to mounting members 200A, 200B and partially positioned in a first recess 246 or a second recess 276.

[0514] The insert body 302 has an upward surface 304 positioned between hooks 308, 312. At least one recess 314 extends upward from the upward surface. In some embodiments, the insert body 302 includes two recesses. In at least one embodiment, three recesses 314 are formed on the grounding insert. One or more recesses provide contact with the frame 198 of the PV module to electrically bond and ground the frame 198 of the PV module 196 to the mounting assemblies 18D, 18E.

[0515] The grounding insert 300 is made of a conductive material. In some embodiments, the grounding insert 300 comprises stainless steel. It should be noted that stainless steel provides increased strength such that the grounding insert 300 is positioned in the corresponding recesses 246, 276 without requiring further modification of the mounting members 200A, 200B (e.g., from their original compressed state) to receive fasteners, press-fit pins, etc., for engaging and grounding the frame 198 of the PV module 196 to the PV platforms 240, 270. However, other materials (and other metals) are conceivable.

[0516] The mounting bracket 20 of the embodiments of this disclosure offers numerous benefits. For example, the mounting bracket 20 described herein accommodates a variety of trapezoidal ribs of different shapes and sizes. Some embodiments of the mounting bracket 20 of this disclosure are adjustable from a minimum width of about 0.67 inches (17.04 mm) to a minimum width of about 3.75 inches (95.18 mm). Therefore, instead of storing many different mounting devices to accommodate a variety of different trapezoidal ribs, the mounting bracket of this disclosure can be used on a variety of different trapezoidal ribs, thereby reducing inventory costs associated with ordering, shipping, storing, and considering a variety of sizes and types of mounting devices. In this regard, this disclosure provides a solution to address the long-standing but unresolved need for mounting brackets that are adjustable to engage trapezoidal ribs of different shapes and sizes and can be used to mount various structures on building surfaces.

[0517] In some embodiments, the mounting bracket 20 is formed of an aluminum alloy. This is advantageous because aluminum is lighter than other materials often used to form mounting devices, resulting in lower transportation costs.

[0518] Another advantage of the mounting brackets 20 in the embodiments of this disclosure is that they are formed without welding. Specifically, the mounting brackets 20 in all embodiments of this disclosure are formed by bending or shaping a metal blank (e.g., a continuous sheet of metal from a roll). In contrast, some known mounting devices for trapezoidal ribs are formed by welding or otherwise joining multiple metal pieces together. As those skilled in the art will understand, forming mounting devices by welding is time-consuming and expensive.

[0519] Another advantage is that the mounting bracket 20 in all embodiments of this disclosure can be used to mount photovoltaic modules onto trapezoidal rib panels with or without guide rails. Furthermore, the mounting bracket 20 reduces the need for fasteners to extend to the underlying deck or another surface (e.g., purlins) beneath the trapezoidal rib panel. This feature of the mounting bracket 20 provides significant flexibility when arranging and mounting photovoltaic modules on a roof formed by trapezoidal rib panels.

[0520] While various embodiments of the systems and methods have been described in detail, it will be apparent to those skilled in the art that modifications and alterations to these embodiments will occur. It should be clearly understood that such modifications and alterations are within the scope and spirit of this disclosure. Furthermore, it should be understood that the wording and terminology used herein are for descriptive purposes and should not be construed as limiting. The use of “comprising,” “including,” or “having,” and variations thereof herein is intended to cover items listed thereafter and their equivalents, as well as additional items. Moreover, it should be understood that the claims are not necessarily limited to the specific features or steps described herein. Rather, the specific features and steps are disclosed as embodiments for implementing the claimed systems and methods.

[0521] One aspect of this disclosure includes any of one or more aspects / exercises substantially disclosed herein.

[0522] Another aspect of this disclosure is any one of the one or more aspects / embodiments substantially disclosed herein, optionally in combination with any one of the other one or more aspects / embodiments substantially disclosed herein.

[0523] Another aspect of this disclosure is to provide one or more apparatuses adapted to perform any of the above-described aspects / embodiments substantially disclosed herein.

[0524] To provide additional background and context and to further satisfy the written description requirements of 35 U.S.SC § 112, the following references are incorporated herein by reference in their entirety: U.S. Patent 8,833,714; U.S. Patent 9,611,652; U.S. Patent 10,443,896; and U.S. Patent 10,903,785.

Claims

1. A mounting bracket having an adjustable width to engage a trapezoidal rib projecting from a building surface, the mounting bracket comprising: The first leg, the first leg includes: A first flange having a first opening; and The first foot is connected to the first flange via a first bend. The first foot includes a first outer surface, a first inner surface opposite to the first outer surface, and a first hole extending through the first inner surface and the first outer surface, wherein when the mounting bracket is fixed to the trapezoidal rib, a first portion of the first inner surface faces the first rib sidewall of the trapezoidal rib. The second leg, the second leg includes: A second flange having a second opening; and The second foot, connected to the second flange via a second bend, includes a second outer surface, a second inner surface opposite to the second outer surface, and a second hole extending through the second inner surface and the second outer surface, wherein when the mounting bracket is secured to the trapezoidal rib, a first portion of the second inner surface faces the second rib sidewall of the trapezoidal rib; and A fastener comprising a shaft operable to extend through a first aperture and a second aperture to interconnect the first leg to the second leg at an interconnection point.

2. The mounting bracket of claim 1, wherein the first foot extends from the first leg in a longitudinal direction, and the second foot extends from the second leg in the same longitudinal direction.

3. The mounting bracket according to claim 1, wherein at least one of the following: The first foot includes a first upper section connected to a first lower section via a first fold, wherein a first portion of the first inner surface is associated with the first lower section of the first foot; and The second foot includes a second upper section connected to the second lower section via a second fold, wherein a first portion of the second inner surface is associated with the second lower section of the second foot.

4. The mounting bracket according to claim 3, wherein at least one of the following: The first fold extends from the first flange, substantially perpendicular to the first surface of the first flange; and The second fold extends from the first surface of the second flange, which is generally perpendicular to the second flange.

5. The mounting bracket according to claim 3, wherein at least one of the following: The first upper segment of the first foot is oriented at a first tilt angle relative to the first lower segment of the first foot; and The second upper section of the second foot is oriented at a second tilt angle relative to the second lower section of the second foot.

6. The mounting bracket according to claim 3, wherein at least one of the first upper section of the first foot, the first lower section of the first foot, the second upper section of the second foot, and the second lower section of the second foot is generally planar.

7. The mounting bracket of claim 3, wherein the first bend is formed between the first flange and at least one of the first lower section and the first upper section of the first foot; and / or The second curved portion is formed between the second flange and at least one of the second lower section and the second upper section of the second foot.

8. The mounting bracket according to claim 1, wherein at least one of the following: The first opening of the first flange is a first elongated slot; and The second opening of the second flange is a second elongated slot.

9. The mounting bracket according to claim 1, wherein at least one of the first aperture and the second aperture is unthreaded.

10. The mounting bracket according to claim 1, wherein at least one of the following: The first leg is a single-piece construction and is formed from a single piece of metal material; and The second leg is a single-piece construction and is formed from a single piece of metal material.

11. The mounting bracket of claim 1, wherein the first hole extends through a first portion of the first inner surface such that when the mounting bracket is secured to the trapezoidal rib, the shaft of the first fastener can extend through the first hole and the sidewall of the first rib to terminate in the hollow interior of the trapezoidal rib.

12. The mounting bracket according to claim 1, further comprising an angle bracket, the angle bracket comprising: A first arm, the first arm having one or more of a first opening and a second opening; and A second arm having an attachment opening, wherein the shaft of the fastener may selectively extend through the first opening or the second opening to interconnect the angular bracket to the first leg and the second leg.

13. The mounting bracket according to any one of claims 1 to 12, wherein the shaft of the fastener defines a pivot axis, and wherein after the first leg is interconnected to the second leg via the shaft of the fastener, the first leg and the second leg are selectively rotatable about the pivot axis.

14. A mounting member for interconnecting photovoltaic modules to a mounting bracket having an adjustable width and capable of being secured to a trapezoidal rib projecting from a building surface, the mounting member comprising: A body having a top end including a top surface; A top opening that extends through the top surface; A first PV platform extends outward from a first side of the mounting component, wherein the first PV platform includes a first upper surface adapted to selectively support a photovoltaic module; and An aperture extending through a first side of the mounting member, the aperture being configured to receive a fastener shaft to interconnect the mounting member to the mounting bracket.

15. The mounting component according to claim 14, further comprising: A groove within a first upper surface of the first PV platform, wherein the groove is operable to receive a grounding insert having at least one recess, the at least one recess extending upward to engage the frame of the photovoltaic module when selectively supported.

16. The mounting member of claim 15, wherein the grounding insert received by a groove on the first upper surface of the first PV platform includes one or more hooks to engage one or more ends of the first PV platform.

17. The mounting component according to claim 14, further comprising: A second PV platform extends outward from the second opposite side of the mounting component, wherein the second PV platform includes a second upper surface adapted to selectively support a second photovoltaic module.

18. The mounting member of claim 17, wherein the first PV platform has a first length in a first direction extending outward from a first side of the mounting member, wherein the second PV platform has a second length in a second direction extending outward from a second opposite side of the mounting member, and wherein the first length is longer than the second length.

19. The mounting member according to claim 17, wherein at least one of the following: The first PV platform has a first stop near a first side of the mounting member, wherein the frame of the photovoltaic module contacts the first stop when selectively supported by the first PV platform, and wherein the first stop is configured to space the frame of the photovoltaic module from a central reference plane passing through the body by a first predetermined distance; and The second PV platform has a second stop near the second opposite side of the mounting member, wherein the frame of the second photovoltaic module contacts the second stop when selectively supported by the second PV platform, and wherein the second stop is configured to space the frame of the second photovoltaic module from a central reference plane passing through the body by a second predetermined distance. The second predetermined distance is substantially equal to the first predetermined distance.

20. The mounting component of claim 17, wherein a portion of the first upper surface of the first PV platform and a portion of the second upper surface of the second PV platform are both approximately planar, and wherein the first upper surface of the first PV platform and the second upper surface of the second PV platform are approximately coplanar.

21. The mounting member of claim 14, wherein the cavity extends through the body between a first end and a second end of the body.

22. The mounting member of claim 21, wherein the top orifice extends through the top surface and into the cavity.

23. The mounting component according to claim 14, wherein the body is a single-piece construction and is formed from a single piece of metal material.

24. The mounting member of claim 14, wherein the top opening is threaded, wherein the internal thread of the top opening has a pitch, and wherein the depth of the top opening is at least 2.5 times the pitch, such that the external thread of the clamping fastener engaging the internal thread will have at least 2.5 turns within the top opening to prevent thread failure.

25. The mounting member according to any one of claims 14 to 24, further comprising a mounting flange extending from a second opposite side of the mounting member, wherein the first PV platform is vertically positioned between the mounting flange and the top surface.

26. The mounting member of claim 25, wherein the mounting flange is positioned in the vertical dimension between the first PV platform and the orifice such that when the mounting flange is interconnected to the mounting bracket, the contact between the mounting flange and the mounting bracket will prevent unintentional rotation of the mounting bracket about the axis of the fastener.

27. An installation system for engaging trapezoidal ribs protruding from a building surface and securing photovoltaic modules to the building surface, the installation system comprising: A mounting bracket with an adjustable width, the mounting bracket comprising: The first leg, the first leg includes: A first flange having a first opening; and The first foot is connected to the first flange via a first bend, wherein when the mounting bracket is fixed to the trapezoidal rib, a first portion of the first inner surface of the first foot faces the first rib sidewall of the trapezoidal rib; The second leg, the second leg includes: A second flange having a second opening; and The second foot, connected to the second flange via a second bend, wherein when the mounting bracket is secured to the trapezoidal rib, a first portion of the second inner surface of the second foot faces the second rib sidewall of the trapezoidal rib; and Fastener, the fastener including a shaft operable to extend through the first aperture and the second aperture to interconnect the first leg to the second leg at an interconnection point; and Mounting component, the mounting component interconnecting the photovoltaic module to the mounting bracket, the mounting component comprising: A body having a top end including a top surface; A top opening that extends through the top surface; A first PV platform extending outward from a first side of the mounting component, wherein the first PV platform includes a first upper surface adapted to selectively support a photovoltaic module; and An aperture extending through a first side of the mounting member, the aperture being configured to receive the shaft of the fastener to interconnect the mounting member to the mounting bracket at the interconnection point.

28. The installation system according to claim 27, further comprising: A clamp adapted to selectively support the photovoltaic module, the clamp being engageable to the top of the mounting member, the clamp including a first leg and a second leg defining a cavity between the first leg and the second leg, wherein the top surface has a width smaller than the width of the cavity defined between the first leg and the second leg, and wherein a portion of the body near the top has a second width greater than the width of the cavity, such that when the clamp is engaged to the top of the mounting member, the first leg provides a frictional engagement with at least a first side of the mounting member.

29. The installation system according to claim 27, further comprising: A second PV platform extends outward from the second opposite side of the mounting component, wherein the second PV platform includes a second upper surface adapted to selectively support a second photovoltaic module.

30. A mounting device for interconnecting photovoltaic modules to a mounting element that can be fixed to a building surface, the mounting device comprising: The main body includes a first side and a second side; A cavity defined by the first side and the second side, the cavity being configured to receive a shaft of a fastener during the interconnection of the mounting member and the mounting element; The first opening within the main body is alignable with a second opening in the mounting element during the interconnection of the mounting member and the mounting element. and A first PV platform extending outward from a first side, wherein the first PV platform includes a first upper surface adapted to selectively support a photovoltaic module.

31. The mounting member of claim 30, wherein the mounting member interconnects the second photovoltaic module to the mounting element, and wherein the mounting member further comprises: A second PV platform extends outward from a second side, wherein the second PV platform includes a second upper surface adapted to selectively support a second photovoltaic module.

Images