Frame and mounting features for photovoltaic modules

Abstract

A frame for a photovoltaic module may include a base portion having an outer lip and a bottom surface while also defining an opening configured to receive a first mounting element therein; at least one leg extending from the base portion; and a panel support portion extending from the at least one leg portion and configured to fix a solar panel therein. The outer lip and the at least one leg may define a cavity.

Description

[0001] Cross-reference to related applications

[0002] This application claims priority to U.S. Provisional Application No. 63 / 527,733, filed July 19, 2023, and U.S. Provisional Application No. 63 / 595,263, filed November 1, 2023, the disclosures of which are incorporated herein by reference in their entirety. Technical Field

[0003] This disclosure relates to frames for photovoltaic modules, as well as support structures and other accessories for the modules and frames. Background Technology

[0004] Photovoltaic modules are typically used in large, multi-module arrays. Some of these systems are used in buildings where space may be limited, necessitating the maximization of the space occupied by the modules. Such an arrangement makes it essential to easily install the modules into their frames so that the combination of modules and frames can be used effectively and efficiently within the system. Therefore, it is desirable to have frames for photovoltaic modules that facilitate rapid installation while effectively utilizing space and minimizing interference with already installed or yet-to-be-installed modules and frames. It is also desirable to have mounting structures and other accessories that can be easily applied to surfaces, such as sloped and flat roofs, using as few equipment and installation steps as possible. Summary of the Invention

[0005] A frame for a photovoltaic module may include: a base portion having an outer lip and a bottom surface, and also defining an opening configured to receive a first mounting element therein; at least one leg extending from the base portion; and a panel support portion extending from the at least one leg and configured to secure a solar panel therein. The outer lip and the at least one leg may define a cavity.

[0006] In some embodiments or aspects, this disclosure may be represented by the following first set of terms:

[0007] Clause 1. A frame for a photovoltaic module, the frame comprising: a base portion including an outer lip and a bottom surface, the base portion defining an opening configured to receive a first mounting element therein; at least one leg extending from the base portion; and a panel support portion extending from the at least one leg, the panel support portion being configured to secure a solar panel therein, wherein the outer lip and the at least one leg define a cavity.

[0008] Clause 2. The frame of clause 1, wherein the base portion further comprises a circular sidewall extending between the bottom surface and the outer lip, the circular sidewall defining the opening.

[0009] Clause 3. The frame of clause 2, wherein the at least one leg extends from a midpoint of the circular sidewall.

[0010] Clause 4. The frame of any one of clauses 1-3, wherein the base portion further comprises at least one pawl extending at least partially into the opening.

[0011] Clause 5. The frame of clause 4, wherein the at least one pawl comprises two pawls, and wherein the two pawls extend into the opening from opposite sides.

[0012] Clause 6. The frame of clause 3, wherein the at least one leg comprises a first leg and a second leg, wherein the first leg extends from a midpoint of the circular sidewall, and wherein the second leg extends from a portion of the base portion proximate to the circular sidewall.

[0013] Clause 7. The frame of any one of clauses 1-6, wherein the cavity is configured to receive a second mounting element therein.

[0014] Clause 8. The frame of clause 7, wherein the first mounting element and the second mounting element are parts of a mounting clip.

[0015] Clause 9. A frame mounting assembly comprising: the frame of clause 8; and a mounting clip configured to mount the frame to a rail, the mounting clip comprising: a base configured to be at least partially secured to a rail; a middle portion configured to be connected to the base, the middle portion comprising at least one extension configured to be received within the opening; a top portion configured to be connected to the base, the top portion comprising at least one mounting lip configured to be received within the cavity.

[0016] Clause 10. The frame mounting assembly of clause 9, wherein the middle portion comprises at least one clip support wing extending a distance beyond the base and the top portion in a direction of the base of the frame, and wherein the extension is at an end of the clip support wing.

[0017] Clause 11. The frame mount assembly of Clause 10, further comprising a fastener, wherein the base defines a first aperture, wherein the top portion defines a second aperture, and wherein the first aperture and the second aperture are configured to receive the fastener therethrough.

[0018] Clause 12. The frame mount assembly of Clause 11, wherein the middle portion includes a body defining a body opening therethrough and a pair of mating walls extending from opposite sides of the body opening, wherein the base includes a channel at least partially defining the first aperture, and wherein the channel is configured to be received through the body opening.

[0019] Clause 13. The frame mount assembly of Clause 12, wherein the top portion defines a hollow extending from a bottom side thereof, the hollow being in communication with the second aperture, and wherein the hollow is configured to receive at least a portion of the pair of mating walls and the channel therein.

[0020] Clause 14. A frame mount assembly comprising: the frame of Clause 8; and a wire dispenser, the wire dispenser comprising: a wire holder defining a wire retention space configured to retain a wire therein; an elongate body extending from the wire holder, the elongate body configured to extend around the base; and a retention extension extending from the elongate body, the retention extension configured to at least partially extend into the opening.

[0021] Clause 15. The frame mount assembly of Clause 14, wherein the wire holder includes a first side wall, a second side wall disposed at a distance away from the first side wall, and a connecting portion extending between the first side wall and the second side wall, and wherein at least a portion of the first side wall abuts at least one leg of the frame.

[0022] Clause 16. The frame mount assembly of Clause 15, wherein the elongate body extends around the base to secure the wire dispenser to the frame.

[0023] Clause 17. The frame mount assembly of Clause 16, wherein the elongate body extends a distance along a top surface of the base, extends around an edge of the base, and extends a distance along a bottom surface of the base.

[0024] Clause 18. The frame mount assembly of Clause 17, wherein the retention extension includes an upward extending portion and a downward extending portion, wherein the upward extending portion at least partially extends into the opening, and wherein the downward extending portion extends in an opposite direction.

[0025] Clause 19. The frame mounting assembly of clause 18, wherein the upwardly extending portion is configured to wedge into the opening, thereby further securing the wire dispenser to the frame.

[0026] Clause 20. The frame mounting assembly of clause 19, wherein the downwardly extending portion is configured to be deflected to disengage the upwardly extending portion from the opening.

[0027] A method of installing a solar panel onto a support surface can include the steps of: installing at least one first mounting component to at least one first support structure, the at least one first mounting component defining a first mounting space and a second mounting space; securing the at least one first support structure to a support surface; installing at least one second mounting component to at least one second support structure, the at least one second mounting component defining a third mounting space and a fourth mounting space; securing a first frame of a solar panel module within the third mounting space; engaging a second frame of the solar panel module with the second mounting space; rotating the solar panel module such that the second frame is rotated within the second mounting space, thereby securing the second frame within the second mounting space; and securing the at least one second support structure to the support surface.

[0028] The at least one first support structure and the at least one second support structure can each include a base defining a slot, a base configured to slide along the slot and to be secured to the slot at a desired location, and a mounting fastener at least partially secured to the base. The mounting fastener can be configured to mount the at least one first mounting component to the at least one first support structure and to mount the at least one second mounting component to the at least one second support structure, and the mounting fastener can be adjustable relative to the base. The method can further include the step of sliding the base of the at least one second support structure to enable the at least one second support structure to be secured to the support surface at a desired location.

[0029] The method can further include a step of securing a base of the at least one second support structure to the slot. The at least one first support structure and the at least one second support structure can further include a base fastener. The base can define a base aperture, and the base fastener can be configured to be received within the base aperture and the slot to secure the base at a desired position. The method can further include a step of adjusting a mounting fastener on at least one of the at least one first support structure and the at least one second support structure to adjust a position of at least one of the at least one first mounting component and the at least one second mounting component. The base can further define a mounting aperture configured to receive the mounting fastener therein. The mounting aperture can extend in a direction orthogonal to the slot. The base aperture can extend in a direction that defines an acute angle with the mounting aperture.

[0030] The at least one first support structure and the at least one second support structure can further include a nut received within the slot, the nut configured to secure the base fastener to the slot. The slot can define a groove, and the nut can be configured to be received within and slide within the groove. The at least one first support structure and the at least one second support structure can further include at least one base fastener, and the base can define at least one base aperture configured to receive the at least one base fastener therein to secure the base to the support surface. The at least one base aperture can include a plurality of base apertures, and the at least one base fastener can include a plurality of base fasteners corresponding to the plurality of base apertures.

[0031] The base can define a bottom surface area. A first portion of the plurality of base apertures can extend into the base in a direction that defines a first angle with the bottom surface area, and a second portion of the plurality of base apertures can extend into the second portion of the plurality of base apertures so as to define a second angle with the bottom surface area, and the second angle can be different than the first angle. The first angle can not be an orthogonal angle, and the second angle can be an orthogonal angle. The first portion of the plurality of base apertures can be disposed about an end of the slot. The second portion of the plurality of base apertures can be disposed on a side of the first portion of the plurality of base apertures opposite the slot.

[0032] The at least one first support structure and the at least one second support structure can further include a pad disposed in the base, the pad being made of a material such that the at least one base fastener can extend through the pad to secure the base to the support surface, the pad can be configured to form a seal between the at least one first support structure and the at least one second support structure and the support surface. The at least one first support structure can include two first support structures, and the at least one mounting component can include two first mounting components corresponding to the two first support structures. The at least one second support structure can include two second support structures, and the at least one second mounting component can include two second mounting components corresponding to the two second support structures. The method can further include the step of engaging a skirt with at least a portion of the first mounting space.

[0033] In some embodiments or aspects, the present disclosure can be represented by a second set of clauses as follows:

[0034] Clause 1. A method of installing a solar panel module onto a support surface, the method comprising the steps of: installing at least one first mounting component to at least one first support structure, the at least one first mounting component defining a first mounting space and a second mounting space; securing the at least one first support structure to a support surface; installing at least one second mounting component to at least one second support structure, the at least one second mounting component defining a third mounting space and a fourth mounting space; securing a first frame of a solar panel module within the third mounting space; engaging a second frame of the solar panel module with the second mounting space; rotating the solar panel module such that the second frame is rotated within the second mounting space, thereby securing the second frame within the second mounting space; and securing the at least one second support structure to the support surface.

[0035] Clause 2. The method of clause 1, wherein the at least one first support structure and the at least one second support structure each comprise: a base defining a slot; a base configured to slide along the slot and to be secured to the slot at a desired location; and a mounting fastener secured at least partially to the base, wherein the mounting fastener is configured to mount the at least one first mounting component to the at least one first support structure and to mount the at least one second mounting component to the at least one second support structure, and wherein the mounting fastener is adjustable relative to the base.

[0036] Clause 3. The method of clause 2, further comprising the step of sliding a base of the at least one second support structure to enable the at least one second support structure to be secured to the support surface at a desired location.

[0037] Clause 4. The method of clause 3, further comprising the step of securing a base of the at least one second support structure to the slot.

[0038] Clause 5. The method of clause 4, wherein the at least one first support structure and the at least one second support structure each further comprise a base fastener, wherein the base defines a base aperture, and wherein the base fastener is configured to be received within the base aperture and the slot to secure the base at a desired location.

[0039] Clause 6. The method of any one of clauses 2-5, further comprising the step of adjusting a mounting fastener on at least one of the at least one first support structure and the at least one second support structure to adjust a position of at least one of the at least one first mounting component and the at least one second mounting component.

[0040] Clause 7. The method of clause 6, wherein the base further defines a mounting aperture configured to receive the mounting fastener therein.

[0041] Clause 8. The method of clause 7, wherein the mounting aperture extends in a direction orthogonal to the slot.

[0042] Clause 9. The method of clause 8, wherein the base aperture extends in a direction that defines an acute angle with the mounting aperture.

[0043] Clause 10. The method of clause 4 or 5, wherein the at least one first support structure and the at least one second support structure further comprise a nut received within the slot, the nut configured to secure the base fastener to the slot.

[0044] Clause 11. The method of clause 10, wherein the slot defines a groove, and the nut is configured to be received within and slide within the groove.

[0045] Clause 12. The method of any one of clauses 2-11, wherein the at least one first support structure and the at least one second support structure further comprise at least one base fastener, and wherein the base defines at least one base aperture configured to receive the at least one base fastener therein to secure the base to the support surface.

[0046] Clause 13. The method of clause 12, wherein the at least one base hole comprises a plurality of base holes, and the at least one base fastener comprises a plurality of base fasteners corresponding to the plurality of base holes.

[0047] Clause 14. The method of clause 13, wherein the base defines a bottom surface area, wherein a first portion of the plurality of base holes extends into the first portion of the plurality of base holes in a direction defining a first angle with the bottom surface area, and a second portion of the plurality of base holes extends into the second portion of the plurality of base holes so as to define a second angle with the bottom surface area, and wherein the second angle is different than the first angle.

[0048] Clause 15. The method of any of clause 14, wherein the first angle is not a right angle, and wherein the second angle is a right angle.

[0049] Clause 16. The method of clause 15, wherein the first portion of the plurality of base holes is disposed about an end of the slot.

[0050] Clause 17. The method of clause 16, wherein the second portion of the plurality of base holes is disposed on a side of the first portion of the plurality of base holes opposite the slot.

[0051] Clause 18. The method of any of clauses 12-17, wherein the at least one first support structure and the at least one second support structure further comprise a pad disposed in the base, the pad being made of a material such that the at least one base fastener can extend through the pad to secure the base to the support surface, and wherein the pad is configured to form a seal between the at least one first support structure and the at least one second support structure and the support surface.

[0052] Clause 19. The method of any of clauses 1-18, wherein the at least one first support structure comprises two first support structures, wherein the at least one first mounting component comprises two first mounting components corresponding to the two first support structures, wherein the at least one second support structure comprises two second support structures, and wherein the at least one second mounting component comprises two second mounting components corresponding to the two second support structures.

[0053] Clause 20. The method of any of clauses 1-19, further comprising the step of engaging a skirt panel with at least a portion of the first mounting space. BRIEF DESCRIPTION OF DRAWINGS

[0054] FIG. 1 front view of a frame for a photovoltaic module according to another embodiment or aspect of the present disclosure;

[0055] FIG. 2 front view of a frame for a photovoltaic module according to another embodiment or aspect of the present disclosure;

[0056] FIG. 3 front view of a frame for a photovoltaic module according to another embodiment or aspect of the present disclosure;

[0057] FIG. 4 front view of a frame for a photovoltaic module according to another embodiment or aspect of the present disclosure;

[0058] FIG. 5 is an example perspective view of a photovoltaic module mounted to a clamp according to another embodiment or aspect of the present disclosure; FIG. 1

[0059] FIG. 6 is an example perspective view of a photovoltaic module mounted to a clamp according to another embodiment or aspect of the present disclosure; FIG. 1

[0060] FIG. 7 is an example perspective view of a photovoltaic module mounted to a clamp according to another embodiment or aspect of the present disclosure; FIG. 1

[0061] FIG. 8 front view of a frame for a photovoltaic module according to another embodiment or aspect of the present disclosure;

[0062] FIG. 9 is a front view of a frame being mounted to a clamp for use in a solar panel system according to an embodiment or aspect of the present disclosure; FIG. 8

[0063] FIG. 10 is a perspective view of a mounting clamp according to an embodiment or aspect of the present disclosure;

[0064] FIG. 11 is a front view of a solar panel frame being mounted to a mounting clamp according to an embodiment or aspect of the present disclosure; FIG. 10

[0065] is a perspective view of a mounting clamp according to an embodiment or aspect of the present disclosure; FIG. 12

[0066] FIG. 13 is an exploded view of a mounting clamp according to an embodiment or aspect of the present disclosure; FIG. 12

[0067] is a first perspective view of a top portion of a mounting clamp according to an embodiment or aspect of the present disclosure; FIG. 12

[0068] is a second perspective view of a top portion of a mounting clamp according to an embodiment or aspect of the present disclosure;​​​​​​​FIG. 12 second perspective view of the top portion of the mounting clip of

[0069] FIG. 16 is a front view of FIG. 12 bottom view of the top portion of the mounting clip of

[0070] FIG. 17 FIG. 17 is a perspective view of the bottom portion of the mounting clip of FIG. 12

[0071] FIG. 18 top view of the bottom portion of the mounting clip of FIG. 12

[0072] FIG. 19 front view of a solar panel frame being removed from the mounting clip of FIG. 12

[0073] FIG. 20 exemplary side view of a solar panel frame mounted to the mounting clip of FIG. 12

[0074] FIG. 21A front view of a solar panel frame and the mounting clip of FIG. 12

[0075] FIG. 21B side view of a solar panel frame and the mounting clip of FIG. 12

[0076] FIG. 22 perspective view of a mounting clip according to one embodiment or aspect of the present disclosure;

[0077] FIG. 23 exploded view of the mounting clip of FIG. 22

[0078] FIG. 24 perspective view of the top portion of the mounting clip of FIG. 22

[0079] FIG. 25 bottom view of the top portion of the mounting clip of FIG. 22

[0080] FIG. 26 bottom view of the top portion of the mounting clip of FIG. 22

[0081] FIG. 27 perspective view of the middle portion of the mounting clip of FIG. 22

[0082] FIG. 28 FIG. 22 ​​​​​​​​​​​​top view of the middle portion of the mounting clip of

[0083] FIG. 29 for FIG. 22 bottom view of the middle portion of the mounting clip of

[0084] FIG. 30 for FIG. 22 perspective view of the bottom portion of the mounting clip of

[0085] FIG. 31 for FIG. 22 top view of the bottom portion of the mounting clip of

[0086] FIG. 32 for FIG. 22 side view of the mounting clip of

[0087] FIG. 33A3 is a side view of the mounting clip of FIG. 22 mounted on a rail, showing one step in the mounting process;

[0088] FIG. 33B for FIG. 22 side view of the mounting clip of

[0089] FIG. 34 perspective view of the mounting clip according to one embodiment or aspect of the disclosure;

[0090] FIG. 34 for FIG. 34 another perspective view of the mounting clip;

[0091] FIG. 35 for FIG. 34 bottom view of the mounting clip of

[0092] FIG. 36 for FIG. 34 exploded view of the mounting clip of

[0093] FIG. 37 front view of two solar panel module frames mounted to the mounting clip of FIG. 38 in an engaged position;

[0094] FIG. 39 front view of the mounting clip of FIG. 34 with two solar panel module frames in a disengaged position;

[0095] FIG. 40 perspective view of the mounting clip according to one embodiment or aspect of the disclosure;

[0096] FIG. 41for FIG. 40 Exploded view of the mounting fixture;

[0097] Figure 42 shows the installation process. FIG. 40 Front view of the two solar panel module frames with the mounting clamps in the joint position;

[0098] FIG. 43 For two solar panel module frames relative to FIG. 40 A front view of the mounting clamp, wherein a portion of the mounting clamp is in the disengaged position;

[0099] FIG. 44 This is a perspective view of a mounting fixture according to an embodiment or aspect of this disclosure;

[0100] FIG. 45 for FIG. 44 A three-dimensional view of the ramp component of the mounting fixture;

[0101] FIG. 46A For solar panel modules installed to FIG. 44 Front view during the installation of the fixture;

[0102] FIG. 46B For solar panel modules installed to FIG. 44 Another front view during the installation of the fixture;

[0103] FIG. 47 To install to FIG. 44 Front view of the two solar panel module frames of the mounting fixture;

[0104] FIG. 48 This is a perspective view of a mounting fixture according to an embodiment or aspect of this disclosure;

[0105] FIG. 49 for FIG. 48 Side view of the mounting fixture;

[0106] FIG. 50 for FIG. 48 Side view of the mounting fixture;

[0107] FIG. 51 for FIG. 48 Exploded view of the mounting fixture;

[0108] FIG. 52 for FIG. 1 Installation to FIG. 48 Side view of the two solar panel module frames of the mounting fixture;

[0109] FIG. 53 A perspective view of a concealed end clamp according to an embodiment or aspect of this disclosure;

[0110] FIG. 54 for FIG. 53 A front view of the concealed end clamp mounted to the track, wherein the track is shown in a transparent manner;

[0111] FIG. 55 for FIG. 53 Side view of the concealed end clamp mounted to the track;

[0112] FIG. 56 To install to FIG. 53 Front view of the solar panel module frame with concealed end clamps;

[0113] FIG. 57 for FIG. 53 Exploded view of the concealed end clamp;

[0114] Figure 58 is FIG. 53 A first perspective view of the track engagement portion of the concealed end clamp;

[0115] Figure 59 is FIG. 53 A second perspective view of the track engagement portion of the concealed end clamp;

[0116] Figure 60 is FIG. 53 A first perspective view of the frame support portion of the concealed end clamp;

[0117] Figure 61 is FIG. 53 A second perspective view of the frame support portion of the concealed end clamp;

[0118] FIG. 62 This is a perspective view of an accessory mounting component according to an embodiment or aspect of this disclosure;

[0119] FIG. 63 for FIG. 62 A three-dimensional view of the accessory installation parts;

[0120] FIG. 64 for FIG. 62 and FIG. 1 Side view of the accessory mounting parts for the solar panel frame connection;

[0121] FIG. 65 for FIG. 64 A 3D view of the accessory installation parts and solar panel frame;

[0122] FIG. 66 for FIG. 64 A 3D view of the accessory installation parts and solar panel frame;

[0123] FIG. 67 A perspective view of a jumper according to an embodiment or aspect of this disclosure;

[0124] FIG. 68 for FIG. 67 Rear-view perspective of the jumper;

[0125] FIG. 69 To show FIG. 67 connection FIG. 1 Side view of the connector that combines the two frames;

[0126] FIG. 70 For example FIG. 69 Rear perspective view of the connecting jumper that connects the two frames shown in the figure;

[0127] FIG. 71 This is a perspective view of a wire laying device according to an embodiment or aspect of this disclosure;

[0128] FIG. 72 for FIG. 71 A front view of the cable runner, in which FIG. 1 The solar panel module frame is installed to the wire layup device;

[0129] FIG. 73 This is a perspective view of a wire clip according to an embodiment or aspect of the present disclosure;

[0130] FIG. 74 for FIG. 73 Installation to FIG. 1 Front view of the wire clamps of the solar panel module frame;

[0131] FIG. 75 for FIG. 74 A 3D view of the wire clips and the solar panel module frame;

[0132] FIG. 76 This is a perspective view of a skirt assembly according to an embodiment or aspect of this disclosure;

[0133] FIG. 77 for FIG. 76 Front view of the skirt panel component;

[0134] FIG. 78 for FIG. 76 Front view of the skirt panel component, in which FIG. 1 The solar panel module frame is installed to the skirt assembly;

[0135] FIG. 79 for FIG. 76 A 3D view of the base of the skirt panel component;

[0136] FIG. 80 for FIG. 76 A perspective view of the connecting parts of the skirt panel assembly;

[0137] FIG. 81 forFIG. 76 perspective view of a skirt of a skirt assembly of

[0138] FIG. 82A perspective view of a support structure according to one embodiment or aspect of the present disclosure;

[0139] FIG. 82B perspective view of a support structure according to one embodiment or aspect of the present disclosure;

[0140] FIG. 83 perspective view of a support structure according to one embodiment or aspect of the present disclosure; FIG. 82A 82B perspective view of a support structure according to one embodiment or aspect of the present disclosure;

[0141] FIG. 84 perspective view of a support structure according to one embodiment or aspect of the present disclosure; FIG. 82A

[0142] perspective view of a support structure according to one embodiment or aspect of the present disclosure; FIG. 85 FIG. 82A 82B perspective view of a support structure according to one embodiment or aspect of the present disclosure;

[0143] FIG. 86 perspective view of a support structure according to one embodiment or aspect of the present disclosure; FIG. 85

[0144] perspective view of a support structure according to one embodiment or aspect of the present disclosure; FIG. 87 FIG. 82A 82B perspective view of a support structure according to one embodiment or aspect of the present disclosure;

[0145] FIG. 88 perspective view of a support structure according to one embodiment or aspect of the present disclosure; FIG. 87

[0146] perspective view of a support structure according to one embodiment or aspect of the present disclosure; FIG. 89 FIG. 87 perspective view of a support structure according to one embodiment or aspect of the present disclosure;

[0147] FIG. 90 FIG. 34 perspective view of a support structure according to one embodiment or aspect of the present disclosure; FIG. 89

[0148] perspective view of a support structure according to one embodiment or aspect of the present disclosure; FIG. 91 FIG. 90 perspective view of a support structure according to one embodiment or aspect of the present disclosure;

[0149] FIG. 92 FIG. 90 perspective view of a support structure according to one embodiment or aspect of the present disclosure;

[0150] FIG. 93 perspective view of a support structure according to one embodiment or aspect of the present disclosure; FIG. 90 FIG. 2 ​​​​​​​​​​​

[0151] FIG. 94 for mounting to a support structure of FIG. 48 FIG. 82A a perspective view of a mounting clip for mounting to a support structure of

[0152] FIG. 95 a side view of a mounting clip and support structure of FIG. 94

[0153] FIG. 96 a cross-sectional side view taken along line B-B of a mounting clip and support structure of FIG. 95

[0154] FIG. 97 a side view of a mounting clip and support structure of FIG. 94 FIG. 2 wherein two solar panel module frames of

[0155] FIG. 98 a perspective view of a mounting clip for mounting to a support structure of FIG. 82B

[0156] FIG. 99 a side view of a mounting clip and support structure of FIG. 98

[0157] FIG. 100 a side view of a mounting clip and support structure of FIG. 98

[0158] FIG. 101 a cross-sectional side view taken along line C-C of a mounting clip and support structure of FIG. 100

[0159] FIG. 102 a side view of a mounting clip and support structure of FIG. 100 wherein two solar panel module frames of

[0160] FIG. 103 a perspective view of a mounting clip for mounting to a support structure of FIG. 82A

[0161] FIG. 104 a side view of a mounting clip and support structure of FIG. 103

[0162] FIG. 105 a cross-sectional side view taken along line D-D of a mounting clip and support structure of FIG. 88

[0163] FIG. 106 ​​​​​​​​​​​for FIG. 103 A side view of the mounting fixture and support structure, wherein two solar panel module frames are mounted to the mounting fixture and the support structure;

[0164] FIG. 107 For installation according to another embodiment or aspect of this disclosure to FIG. 82A A perspective view of the mounting fixture for the support structure shown;

[0165] FIG. 108 for FIG. 107 Side view of the mounting fixtures and support structure;

[0166] FIG. 109 for FIG. 107 Side view of the mounting fixtures and support structure;

[0167] FIG. 110 for FIG. 107 Exploded view of the mounting fixtures and support structure;

[0168] FIG. 111 for FIG. 109 A cross-sectional side view of the mounting fixtures and support structure along line EE;

[0169] FIG. 112 A perspective view of an array of solar panel modules mounted using mounting clamps and support structures according to this disclosure;

[0170] FIG. 113 A perspective view of a single solar panel module installed using mounting clamps and support structures according to this disclosure;

[0171] FIG. 114 A side view of a module framework according to another embodiment or aspect of this disclosure;

[0172] FIG. 115 A side view of a module framework according to another embodiment or aspect of this disclosure;

[0173] FIG. 116 A side view of another module frame according to another embodiment or aspect of this disclosure;

[0174] FIG. 117 This is a perspective view of a mounting fixture according to an embodiment or aspect of this disclosure;

[0175] FIG. 118 for FIG. 117 Exploded view of the mounting fixture;

[0176] FIG. 119 for FIG. 117 A perspective view of the top part of the mounting fixture;

[0177] FIG. 120 for FIG. 117 A top view of the mounting fixture portion;

[0178] FIG. 121 for FIG. 117 A three-dimensional view of the middle part of the mounting fixture;

[0179] FIG. 122 for FIG. 117 Bottom view of the middle part of the mounting fixture;

[0180] FIG. 123 for FIG. 117 A perspective view of the bottom part of the mounting fixture;

[0181] FIG. 124 for FIG. 117 A top view of the bottom portion of the mounting fixture;

[0182] FIG. 125 for FIG. 70 A side view of the skirt assembly, which has been modified to be compatible with... FIGS. 115-117 Adaptation to the module framework;

[0183] FIG. 126 This is a perspective view of a wire clip according to an embodiment or aspect of the present disclosure;

[0184] FIG. 127 for FIG. 126 Installation to FIG. 114 Side view of the wire clips of the module frame;

[0185] FIG. 128 This is a perspective view of another wire clip according to an embodiment or aspect of this disclosure;

[0186] FIG. 129 for FIG. 128 Installation to FIG. 114 Side view of the wire clips of the module frame;

[0187] FIG. 130 This is a perspective view of a one-piece mounting fixture according to an embodiment or aspect of the present disclosure;

[0188] FIG. 131 for FIG. 130 Front view of the mounting fixture;

[0189] FIG. 132 for FIG. 131 Front view of the mounting clamp for mounting onto the track;

[0190] FIG. 133A for FIG. 131 Side view of the mounting fixture during installation onto the track and module frame;

[0191] FIG. 133B Figure 1 1 is a side view of the mounting clip of FIG. 131 Figure 1 1 is a side view of the mounting clip of

[0192] FIG. 134 Figure 1 1 is a side view of the mounting clip of

[0193] FIG. 135 Figure 1 1 is a side view of the mounting clip of FIG. 134 Figure 1 1 is a side view of the mounting clip of

[0194] FIG. 136 Figure 1 1 is a side view of the mounting clip of

[0195] FIG. 137 Figure 1 1 is a side view of the mounting clip of FIG. 136 Figure 1 1 is a side view of the mounting clip of

[0196] FIG. 138 Figure 1 1 is a side view of the mounting clip of FIG. 136 Figure 1 1 is a side view of the mounting clip of FIG. 1 Figure 1 1 is a side view of the mounting clip of

[0197] FIG. 139 Figure 1 1 is a side view of the mounting clip of

[0198] FIG. 140 Figure 1 1 is a side view of the mounting clip of FIG. 139 Figure 1 1 is a side view of the mounting clip of

[0199] FIG. 141 Figure 1 1 is a side view of the mounting clip of FIG. 139 Figure 1 1 is a side view of the mounting clip of FIG. 1 Figure 1 1 is a side view of the mounting clip of

[0200] FIG. 142 Figure 1 1 is a side view of the mounting clip of

[0201] FIG. 143 Figure 1 1 is a side view of the mounting clip of FIG. 142 Figure 1 1 is a side view of the mounting clip of

[0202] FIG. 144 Figure 1 1 is a side view of the mounting clip of FIG. 142 Figure 1 1 is a side view of the mounting clip of FIG. 1 Figure 1 1 is a side view of the mounting clip of

[0203] FIG. 145A Figure 1 1 is a side view of the mounting clip of FIG. 142 Figure 1 1 is a side view of the mounting clip of

[0204] FIG. 145B Figure 1 1 is a side view of the mounting clip of FIG. 142Another rear view of the mounting fixture, showing the fixture being installed onto the track;

[0205] FIG. 145C for FIG. 142 Another rear view of the mounting clamp, showing the mounting clamp being installed onto the track;

[0206] FIG. 146 This is a perspective view of a mounting fixture according to another embodiment or aspect of this disclosure;

[0207] FIG. 147 for FIG. 146 Installation to the track and FIG. 1 A three-dimensional view of the mounting fixture for the modular frame;

[0208] FIG. 148 This is a perspective view of a mounting fixture according to another embodiment or aspect of this disclosure;

[0209] FIG. 149 for FIG. 148 Exploded view of the mounting fixture;

[0210] FIG. 150 for FIG. 148 Installation to the track and FIG. 1 A three-dimensional view of the mounting fixture for the modular frame;

[0211] FIG. 151 This is a perspective view of a mounting fixture according to another embodiment or aspect of this disclosure;

[0212] FIG. 152 for FIG. 151 A top view of the mounting fixture;

[0213] FIG. 153 for FIG. 151 Front view of the mounting fixture;

[0214] FIG. 154 for FIG. 151 Front view of the mounting clamp installed in the track;

[0215] FIG. 155A for FIG. 151 A side view of the mounting clamp, which is mounted in the track and is in a fixed position. FIG. 1 In the process of the first module framework;

[0216] FIG. 155B for Figure 151 A side view of the mounting clamp, which is mounted in the track and is in a fixed position. Figure 1 In the process of the second module framework;

[0217] Figure 156perspective view of a mounting clip according to another embodiment or aspect of the present disclosure;

[0218] Figure 157 perspective view of a mounting clip according to another embodiment or aspect of the present disclosure; Figure 156

[0219] Figure 158 perspective view of a mounting clip according to another embodiment or aspect of the present disclosure; Figure 156 Figure 1

[0220] Figure 159 perspective view of a mounting clip according to another embodiment or aspect of the present disclosure;

[0221] Figure 160 perspective view of a mounting clip according to another embodiment or aspect of the present disclosure; Figure 159

[0222] Figure 161 perspective view of a mounting clip according to another embodiment or aspect of the present disclosure; Figure 159

[0223] Figure 162 perspective view of a mounting clip according to another embodiment or aspect of the present disclosure; Figure 159 Figure 1 perspective view of a mounting clip according to another embodiment or aspect of the present disclosure;

[0224] Figure 163 perspective view of a mounting clip according to another embodiment or aspect of the present disclosure;

[0225] Figure 163 perspective view of a mounting clip according to another embodiment or aspect of the present disclosure;

[0226] Figure 165 Figure 163 perspective view of a mounting clip according to another embodiment or aspect of the present disclosure; Figure 1

[0227] perspective view of a mounting clip according to another embodiment or aspect of the present disclosure; Figure 166 Figure 165 Figure 1 perspective view of a mounting clip according to another embodiment or aspect of the present disclosure; and

[0228] Figure 167 perspective view of a mounting clip according to another embodiment or aspect of the present disclosure. Figure 165 Figure 1 DETAILED DESCRIPTION

[0229] As used herein, the singular forms "a", "an", and "the" include plural referents unless the context clearly dictates otherwise.

[0230] ​​​​​​​​​​​​Spatial or directional terms such as "left," "right," "inner," "outer," "above," "below," "horizontal," "vertical," etc. relate to the disclosure as shown in the drawings and should not be construed as limiting because the disclosure can assume various alternative orientations.

[0231] The terms "first," "second," etc. are not intended to refer to any particular order or chronology, but rather to different conditions, properties, or elements.

[0232] The term "comprising" is synonymous with "including."

[0233] As used herein, the term "parallel" or "substantially parallel" refers to the relative angle between two objects, such as elongated objects and including reference lines, if extended to a theoretical intersection, of 0° to 5°, or 0° to 3°, or 0° to 2°, or 0° to 1°, or 0° to 0.5°, or 0° to 0.25°, or 0° to 0.1° inclusive of the recited values.

[0234] As used herein, the term "perpendicular" or "substantially perpendicular" refers to the relative angle between two objects at their actual or theoretical intersection of 85° to 90°, or 87° to 90°, or 88° to 90°, or 89° to 90°, or 89.5° to 90°, or 89.75° to 90°, or 89.9° to 90° inclusive of the recited values.

[0235] INTRODUCTION

[0236] The present disclosure relates to various features used in conjunction with solar panels to form solar panel modules and to efficiently and effectively arrange these modules in desired locations. Using the features discussed herein, multiple modules can be arranged in an array or just one module can be supported in a particular location. Generally, a solar panel frame is mounted or glued to a photovoltaic panel to form a solar panel module. To support the module, clamps and other mounting structures are used to secure the solar panel module in a desired location. Modules can be mounted to a rail system or a rail-less system, both of which will be discussed herein. The term "mounting structure" will be used throughout the present disclosure and can be understood to refer to either a rail system or a rail-less system. Depending on the context of each embodiment, the mounting structure will be apparent. Modules can be mounted on different support surfaces, such as a flat roof, a sloped roof, or different ground surfaces. While some of the disclosure provided herein can be discussed in conjunction with certain support surfaces or mounting features, one of skill in the art will recognize that the disclosure is not limited to the examples in which they are discussed. Even if not explicitly mentioned, different mounting features can be used in different environments and with different frames or other features with varying degrees of modification.

[0237] Solar panel module frame

[0238] Figures 1-4 Figs. 8 and 114-117 show different embodiments of solar panel frames 102, 202, 302, 402, 802, 11402, 11602. Each embodiment has some similar features, which will be identified with some common reference numbers. Some of these frames will be shown later in this application in conjunction with additional features and accessories. While only one or two of the solar panel frames 102, 202, 302, 402, 802, 11402, 11602 are shown in conjunction with these additional features and accessories, one of skill in the art will understand that all of the solar panel frames 102, 202, 302, 402, 802, 11402, 11602 can be used with each of the additional features and accessories shown in the present disclosure.

[0239] It should be understood that each of the different solar panel frames 102, 202, 302, 402, 802, 11402, 11602 can be mounted to and used with a variety of different mounting features. In this disclosure, the solar panel frames 102, 202, 302, 402, 802, 11402, 11602 will be discussed in connection with different mounting clamps and other accessories. In the drawings, only one of the solar panel frames 102, 202, 302, 402, 802, 11402, 11602 is shown in connection with these other features. However, it should be understood that the other frames 102, 202, 302, 402, 802, 11402, 11602 can still be used with those other features. In some cases, slight modifications to the frames 102, 202, 302, 402, 802, 11402, 11602 or the features can be needed to adapt a certain frame 102, 202, 302, 402, 802, 11402, 11602 to the other features, but these modifications will be apparent to those skilled in the art. However, if only one of the solar panel frames 102, 202, 302, 402, 802, 11402, 11602 is discussed in connection with a clamp, this does not exclude that the other frames 102, 202, 302, 402, 802, 11402, 11602 can also be used with that clamp.

[0240] Many such clamps are mounted to rails R that extend beneath a plurality of solar panels arranged in a solar panel array. The rails R are configured to receive the clamps in order to mount one or more solar panels along different positions of each rail R. Different clamps can be arranged on different rails R, with each clamp mounted to the same independent frame 102, 202, 302, 402, 802, 11402, 11602. The solar panel frames 102, 202, 302, 402, 802, 11402, 11602 can also be mounted to rail-less systems, which can or can not include the clamps discussed in this disclosure. Examples of such rail-less systems are various types of roof attachments and rail-less mounts. In some embodiments, these rail-less systems can support one to four solar panel modules. When the solar panel frames 102, 202, 302, 402, 802, 11402, 11602 are mounted to systems that do not use the clamps encompassed by this disclosure, the mounts will include features that facilitate the mounting of the solar panel frames 102, 202, 302, 402, 802, 11402, 11602. The mounting process contemplated by this disclosure can or can not require tools to properly place a single solar panel module within an array. The solar panel frames 102, 202, 302, 402, 802, 11402, 11602 can also be used in conjunction with metal roof mounts, such as seam clamps or corrugated roof mounts. The solar panel frames 102, 202, 302, 402, 802, 11402, 11602 shown and described in FIGS. 1-15 will now be discussed. Figures 1-8

[0241] Referring to Figure 1 ​The solar panel frame 102 includes a base 104 that extends along the bottom of the frame 102. The base 104 includes a generally flat central portion 106 and an outer lip 108 that extends from the central portion 106. As shown in the figures, the outer lip 108 curves upward a distance away from the central portion 106. Legs 110A, 110B extend away from the base 104 in generally the same direction as the outer lip 108. The first leg 110A extends from the outer lip 108 and the second leg 110B extends from the central portion 106. The first leg 110A and the outer lip 108 define a clip cavity 112, which is the space between these two elements that is configured to receive a clip or other solar panel mounting feature therein to secure the frame 102 within a solar panel array. The engagement between these features will be discussed below. The shape or angle of the outer lip 108 can be set to engage a clip or mounting feature, securing the feature to the outer lip and at least partially in the clip cavity 112. The outer lip 108 can also be resilient so as to bend when installed to a clip. The outer lip 108 can also provide an audible or tactile indication of engagement with a clip. The legs 110A, 110B define a hollow center 110C therebetween. Although two legs 110A, 110B are shown, one of ordinary skill in the art will appreciate that any number of legs can be used so long as the panel support portion 114 is adequately supported above the base 106.

[0242] Still referring to Figure 1The solar panel frame 102 includes an inner base extension 130 that extends inwardly from the base 104 in a direction opposite the outer lip 108. The base extension 130 can interact with features of various accessories and other structures to facilitate connection of various other accessories and structures to the frame 102, as will be explained further below. The panel support portion 114 extends from and is supported by the leg portions 110A, 110B. The panel support portion 114 defines a panel cavity 116 arranged to receive a solar panel therein. The panel support portion 114 includes a panel support surface 118 for seating a solar panel thereon. The body defining the panel support portion 114 extends across the leg portions 110A, 110B. The panel support surface 118 can be uneven so as to define a lip, groove, or ridge that can be used to secure a solar panel within the cavity 116. A sidewall 120 extends upwardly from the panel support surface 118, and a top wall 122 extends from the sidewall 120 generally parallel to the panel support surface 118. The top wall 122 includes an adhesive flare 124 at a terminal end and a panel lip 126 that define an adhesive space 128 therebetween. The adhesive space 128 can hold an adhesive that can help secure a solar panel within the cavity 116. The panel lip 126 can also help retain a solar panel within the cavity 116 by providing a surface that can accommodate adhesive and / or frictionally engage an edge of a solar panel.

[0243] Referring to Figure 2 A second solar panel frame 202 is shown. This solar panel frame 202 includes the same features as the first solar panel frame 102, except that the first leg portion 210A extends from the center portion 206, rather than from the outer lip 208. This arrangement enables a deeper clip cavity 212 to be formed, which can accommodate different clips or mounting features.

[0244] Referring to Figure 3 A third solar panel frame 302 is shown. This solar panel frame 302 is similar to the second solar panel frame 202 in that the first leg portion 310A extends from the center portion 306. However, this solar panel 302 includes a flange 330 that extends from the center portion 306 in a direction opposite the direction in which the outer lip 318 initially extends from the center portion 306. The flange 330 can engage with other mounting features or accessories, such as an end clip or a wire clip, as will be discussed below. While the first solar panel frame 102 and the second solar panel frame 202 appear to exhibit flanges that extend beyond their respective second leg portions 110B, 210B, these extensions are not flanges, but rather are the result of the leg portions 110B, 210B being cut away to accommodate the clip cavities 112, 212. Figure 3The flanges 330 shown in FIG. 3 are short. These short extensions 130, 230 of the bases 104, 204 beyond the second leg portions 110B, 210B can still engage with certain mounting accessories discussed below. For certain clamping systems that include fasteners and flange holes that enable an installer to connect the frame 302 to a mounting structure from below, flanges 330 with greater area can be used.

[0245] Referring to FIG. 4, Figure 4 a fourth solar panel frame 402 is shown. This solar panel frame 402 includes a circular center portion 406 along the base 404. This circular center portion 406 means that the flanges 430, if present, extend a distance from the center portion 406 above the bottom of the frame 402. The circular center portion 406 enables the frame 402 to be more easily rocked or rotated into position relative to a clamp or other mounting feature. Figures 29-31 The clamp-ramp piece mounting system shown in FIG. 3 is an example of this. The circular center portion 406 also serves as a guide for rotating the frame within the clamp when used with the clamp-ramp piece mounting system, and the flanges 430 serve as stops against the ramp pieces, which enables the module frame 402 to be better captured and held within the system.

[0246] Referring back to FIG. 1, Figure 1 It is contemplated that the length of the outer lip 108 of the frame 102 relative to the solar panel frame 102 is greater than lengths known in the prior art. For example, the length L0 of the solar panel frame 102 from the base 104 to the portion of the top wall 122 that is farthest from the base can be 25-40 mm (0.98-1.57 inches), and the length LI of the outer lip 108 can be 5-12 mm (0.19-0.47 inches). In this example, the outer lip 108 ranges from 20-40% of the total length L0 of the solar panel frame 102. In a particular example, the outer lip 108 can have a length LI of 8.89 mm (0.35 inches). In other examples, the outer lip 108 can even be longer. These lengths and their ratios help the solar panel frame 102 to be more securely and easily connected with its respective clamp, which is discussed below. It should be understood that these lengths L0, LI can also apply to the frames 202, 302, 402 and outer lips 208, 308, 408 of other embodiments.

[0247] Referring to FIG. 4, Figures 5-7The method of installing the frame 102 to the clamp C will now be described. The clamp C is intended to exemplarily generally describe the installation process from the perspective of the frame 102. The specific installation clamps that can be used with the frames discussed in this section will be discussed later. The solar panel frames 202, 302, 402 are installed in a similar manner and one of ordinary skill in the art will understand the installation method of these frames 202, 302, 402 based on the present disclosure. It should also be understood that the frame 102 can be installed to other features in a similar manner, some of which will be discussed below.

[0248] First, the frame 102 is tilted at an angle such that at least the end of the installation lip L of the installation clamp is received within the clamp cavity 112. Next, the frame 102 is rotated downward in the direction of the feature to which the installation clamp C is connected. This rotation continues until the bottom surface of the frame 102 fully contacts the feature to which the clamp C is connected. As the frame 102 is rotated, a clicking or clunking sound can be emitted due to the contact between the installation lip L and the tilted outer lip 108. Such a sound can indicate the engagement between the installation lip L and the outer lip 108 and the clamp cavity 112. Once engaged, the frame 102 can be slid along the installation element in the direction of entering or exiting the page in order to adjust its placement within the solar panel array. To complete the installation process, the opposite side of the solar panel, which is also connected to the frame 102, is then tilted downward after the outer lip 108 is engaged with the clamp cavity 112. This opposite side can also be engaged with its own clamp C to fully secure the solar panel in the desired position. The installation lip L can exert a downward force on the frame 102 when the installation lip L is held within the clamp cavity 112 and the bottom surface fully contacts the installation element, which serves to secure the frame 102 in place. Figure 7

[0249] Reference is made to Figure 8 ​A fifth solar panel frame 802 is shown in FIG. 8B. This solar panel frame 802 does not have an outer lip and has a clip cavity 832 defined entirely by the first leg 810A. The clip cavity 832 is semi-circular, but other shapes can be used depending on the shape of the clip that will be installed in the clip cavity 832. As shown in the figure, the clip cavity 832 is raised so as to be closer to the solar panel support portion 814 than the base 804. However, other placements of the cavity 832 along the leg 810A would be understandable. The top of the leg 810A and the bottom edge of the clip cavity 832 define a male lip 833 that is used to secure the frame 802 to a clip, which will be discussed below. A connecting portion 834 extends from the first leg 810A at the location of the cavity 832, the connecting portion extending from the first leg 810A to the second leg 810B. The connecting portion 834 improves the strength and durability of the frame 802. To further improve the strength of the frame 802 or any other frame 102, 202, 302, 402, 11402, 11602 discussed herein, the thickness of the frame portions can be increased. Due to the connecting portion 834 extending between the legs 810A, 810B, there are two hollow center portions 810C1, 810C2.

[0250] Referring to Figure 9FIG. 9 shows the installation of a solar panel frame 802 to a clamp 900. The clamp 900 is connected to a support structure, such as the rail R shown. The support structure can be various mounts, rails, or other structures configured to support a solar panel array. The clamp 900 is used to securely and clippably connect a solar panel to the rail R or other support structure. The clamp 900 includes a body 902, which is shown as generally quadrilateral. It should be understood that the body 902 can take other shapes, so long as it is able to be installed to the solar panel frame 802. Installation lips 904A, 904B extend from opposite sides of the body. The installation lips 904A, 904B are circular and are shaped to fit within and configured to cooperate with the convex lip 833 and concave cavity 832 formed in the first leg 810A of the frame 802. The installation lips 904A, 904B define circular concave grooves 906A, 906B on their bottom surfaces. The circular concave grooves 906A, 906B of the installation lips 904A, 904B are configured to receive and interact with the convex lip 833 defined by the leg 810A and cavity 832 to secure the solar panel frame 802 to the mounting structure. The installation lips 904A, 904B and clamp cavities 906A, 906B can have different shapes, so long as there is an engagement between the corresponding components of the frame 802 and clamp 900. The installation lips 904A can include teeth, knurling, or other knurled features that assist in binding to the frame 802 within the clamp cavities 906A, 906B. Similar features can also be included in the clamp cavities 906A, 906B.

[0251] To clippably install the solar panel frame 802 to the rail R using the clamp 900, the solar panel should be tilted or angled so that the frame 802 is angled or rotated relative to the rail R or other support structure and clamp 900. This lowers the convex lip 833 of the clamp 802 relative to its respective installation lips 904A, 904B so that the bottom edge of the convex lip 833 or cavity 832 can pass under the installation lips 904A, 904B. Thereafter, the solar panel module can be lowered and the frame 802 can be rotated so that the convex lip 833 of the clamp 802 is aligned with the installation lips 904A, 904B. The convex lip 833 can then be lowered into the installation lips 904A, 904B, and the solar panel frame 802 can be secured to the clamp 900 and rail R or other support structure. Figure 6The frame 802 is rotated in the direction of the arrow shown in FIG. 8A, so that the bottom edge of the clamp cavity 832 and the convex lip 833 rotate around and within the concave groove 906A of the mounting lip 904A. This rotation continues until the outer surface of the first leg 510A contacts the nearest surface of the clamp body 902. The rotation raises the cavity 832 relative to the mounting lip 904A, which causes the convex lip 833 to contact and provide an upward force on the mounting lip 904A. This raises the mounting lip 904A to some extent and causes the mounting lip 904A to provide a downward acting clamping force that is opposite to the upward force created by the clamp cavity 906. This downward force helps to clamp the frame 802 in place relative to the clamp 900 and the rail R. The solar panel frame 802 and the clamp body 902 should both be shaped so that when the solar panel held within the frame 802 is at its desired position within the array, the rotation of the solar panel frame 802 stops and full engagement is achieved between the clamp cavity 906 and the single mounting lip 904A. As shown in FIG. 8B, the frame 802 is rotated in the direction of the arrow shown in FIG. 8B, so that the bottom edge of the clamp cavity 832 and the convex lip 833 rotate around and within the concave groove 906B of the mounting lip 904B. This rotation continues until the outer surface of the second leg 510B contacts the nearest surface of the clamp body 902. The rotation raises the cavity 832 relative to the mounting lip 904B, which causes the convex lip 833 to contact and provide an upward force on the mounting lip 904B. This raises the mounting lip 904B to some extent and causes the mounting lip 904B to provide a downward acting clamping force that is opposite to the upward force created by the clamp cavity 906. This downward force helps to clamp the frame 802 in place relative to the clamp 900 and the rail R. The solar panel frame 802 and the clamp body 902 should both be shaped so that when the solar panel held within the frame 802 is at its desired position within the array, the rotation of the solar panel frame 802 stops and full engagement is achieved between the clamp cavity 906 and the single mounting lip 904B. Figure 6 and 7 As shown in FIG. 8A, this position is achieved when the solar panel frame 802 is substantially upright on the top of the rail R. As shown in FIG. 8B, this position is achieved when the solar panel frame 802 is substantially upright on the top of the rail R. As shown in FIG. 8C, this position is achieved when both solar panel frames 802 are upright on the top of the rail R, with the respective clamp cavities 906 of the two solar panel frames engaged with the mounting lips 904A, 904B.

[0252] A unique installation process and method is achieved by the upward force generated by the rotation of the frame 802 against the clamp 900, specifically against the mounting lips 904A and 904B. The panel frame 802 can be installed into the clamp 900 after the clamp 900 has been securely fixed and connected to the track R or other support structure. This eliminates the need to position the panel correctly on the support structure or track R before tightening the clamp. This makes it easier to access the clamp 900 for tightening, as the installer 25 no longer needs to reach over the panel to tighten the clamp 900. Additionally, the mounting lips can be preset at a certain height above the track R or other support structure so that the clamp 900 can slide along the mounting structure toward the frame 802, which is already in its desired final position on the mounting structure. Here, the installer slides the clamp 900 along the mounting structure until one of the mounting lips 904A and 904B extends into the cavity 832, and the concave recesses 908A and 908B receive and capture their respective convex lips 833. Then, as described above, another panel can be installed and rotated into clamp 900. This process can be repeated until all adjacent panels in a row or column have been installed. This additional method improves ease of installation, reduces the time and labor required to complete the installation, eliminates the use of tools for tightening fasteners, and minimizes small parts and loose fasteners that may easily fall off the roof or other mounting surfaces and be lost.

[0253] Installation clamps

[0254] refer to Figure 10 and 11 The lower fastening clamp 1000 is shown. The lower fastening clamp 1000 is shown as being connected to... Figure 1solar panel frame 102, but it should be understood that other solar panel frames can be used with the underside fastening clamp 1000 in a similar or identical manner. The underside fastening clamp 1000 has a generally quadrilateral body 1004. However, other shapes can be used. A first mounting lip 1006A extends from a first side of the body 1004. A second mounting lip 1006B extends from a side of the body 1004 opposite the first side. Both mounting lips 1006A, 1006B are shaped to engage with the clamp cavity 112 of the solar panel frame 102. The mounting lips 1006A, 1006B are shaped as hooks to engage with the outer lip 108 of the solar panel frame 102. This shape allows the outer lip 108 or the cavity 112 to have an audible or tactile engagement with the mounting lips 1006A, 1006B, which indicates that the solar panel frame 1210 has been properly installed. On the last two sides of the clamp body 1004 are shields 1008. The shields 1008 extend from the body 1004 to a lower position than the mounting lips 1006A, 1006B to provide a cover for the fasteners 1010. The shields 1008 act as spacers to fix the mounting lips 1006A, 1006B at a desired height above the mounting surface in order to achieve the clamping function of the mounting lips 1006A, 1006B on the panel frame 102.

[0255] The fasteners 1010 are located in the center of the clamp body 1004 and extend from the bottom surface thereof. The fasteners 1010 and the body 1004 can be fixed together so that they do not rotate independently of one another. A fastener nut 1012 is shown extending a short distance from the top surface of the clamp body 1004 to indicate the position of the fasteners 1010 relative to the clamp body 1004. The fasteners 1010 are arranged to allow the underside fastening clamp 1000 to be mounted from below to a rail R, mounting structure, or other device. The nuts 1012 or other fastening devices are applied to the fasteners 1010 to tighten them in place against the mounting surface of the mounting structure to which the underside fastening clamp 1000 and solar panel module are mounted. By fastening the clamp 1000 from below, the mounting features, such as the nuts 1012, are easily accessible. The underside fastening clamp 1000 also includes grounding teeth 1014A, 1014B on opposite sides of the body 1004. These teeth 1014A, 1014B bite into the outer lip 108 of the solar panel frame 102 to facilitate the bonding and electrical grounding between the solar panel frame 102 and the underside fastening clamp 1000 and further to the mounting structure or rail R. It is also contemplated that teeth can be added to the distal edges of the mounting lips 1006A, 1006B so that the teeth will bite into the top surface of the cavity 112, 212, 312, 412.

[0256] ReferringFigures 12-2 1, showing a mounting clamp 1200. The mounting clamp 1200 is a rotary clamp, and can be so referred to. The rotary clamp 1200 includes a base 1202, a channel portion 1206 extending from the base 1202, and a top portion 1208 covering the channel portion 1206. The top portion 1208 defines a hole Al, and the channel portion 1206 defines a hole A2 that aligns with the hole Al to receive a fastener 1218 therethrough to connect the parts. The fastener 1218 includes an elongated portion 1234 received through both holes Al, A2, and a head 1236 seated against the top portion 1208 around the hole Al. The fastener 1218 provides a downward force that holds the top portion 1208 against the channel portion 1206. A spring 1220 is held within the channel hole A2 and fits around the fastener 1218. The spring 1220 contacts a bottom surface of the top portion 1208 and pushes the top portion 1208 upward against the force of the fastener 1218. The top portion 1208 and the channel portion 1206 include complementary features that facilitate operation of the rotary clamp 1200, which will be described in more detail below.

[0257] The top portion 1208 includes a first mounting lip 1214A and a second mounting lip 1214B. The mounting lips 1214A, 1214B extend outward in opposite directions perpendicular to the axis defined by the hole Al. Like the other mounting lips discussed so far, the mounting lips 1214A, 12014B are configured to engage corresponding lips and cavities on a solar panel frame. The top portion 1208 includes a gripping ridge 1216 on the top surface that engages the head of the fastener 1218 when the elongated portion 1234 is received within the holes Al, A2 to secure it in place. The gripping ridge 1216 also serves to transfer rotational force from the fastener 1218 to the top portion 1208, which will be discussed below. The top portion has guides 1210A, 1210B extending downward from its top surface. The guides 1210A, 1210B extend from opposite sides of the top portion 1208 adjacent to the mounting lips 1214A, 1214B. The guides 1210A, 1210B correspond to ramps 1211A, 1211B located on the channel portion 1206, which will be discussed below.

[0258] The channel portion 1206 includes a channel body 1221 around which the ramps 1211A, 1211B extend. The channel body 1221 defines a bore A2 and includes a sidewall 1222 that defines a fastener channel 1223 for receiving the elongated portion 1234 of the fastener 1218. The fastener channel 1223 includes a stepped space 1224 defined by a step 1225 and the sidewall 1222, and a threaded space 1226 below the stepped space 1224, where the sidewall 1222 is threaded for engaging corresponding threads on the fastener 1218. The stepped space 1224 is wider in diameter than the threaded space 1226. The stepped space 1224 provides a larger space to hold the spring 1220. In particular, the spring 1220 can be supported by the step 1225, with the sidewall 1222 of the stepped space 1224 surrounding the spring. In this arrangement, the stepped space 1224 is sized to support the spring 1220, and the threaded space 1226 is sized to engage the fastener 1218.

[0259] The channel portion 1206 can be integrally formed with or keyed together with the base 1202, meaning that the channel portion 1206 and the base 1202 cannot rotate relative to each other. The base 1202 is wide enough to be supported within the track R, as partially shown in FIG. 21. The base 1202 includes base wings 1203A, 1203B extending from opposite sides of the channel portion 1206. The ends of the base wings 1203A, 1203B define slots 1205A, 1205B that are configured to engage portions of the track R to further stabilize the rotary clamp 1200 within the track R. Examples of these portions can be corresponding slots or channels located within the track R, such that the base 1202 can act as a channel nut within the track R.

[0260] The rotary clamp 1200 operates due to the interaction between features of both the channel portion 1206 and the top portion 1208. First and second ramps 1211A, 1211B extend around the channel body 1221. The ramps 1211A, 1211B can extend symmetrically or asymmetrically around the channel body 1221, as long as they function as described herein. The ramps 1211A, 1211B increase in height circumferentially around the channel body 1221 until they terminate at about the same height as the highest surface of the channel body 1221. First and second guides 1210A, 1210B correspond to the ramps 1211A, 1211B. When the fastener 1218 is tightened by rotating the elongated portion 1234 through the threaded space 1226 of the fastener channel 1223, the top portion 1208 is pushed downward toward the base 1202, and the guides 1210A, 1210B engage the circumferentially sloped top surfaces of the ramps 1211A, 1211B, which causes the top portion 1208 to rotate around the channel portion 1206. This downward force created by tightening the fastener 1218 overcomes the upward force created by the spring 1220, which is discussed below. When the top portion 1208 is at its lowest position relative to the other elements of the clamp 1200 and the fastener 1218 is fully engaged with the threaded space 1226, the mounting lips 1214A, 1214B are disposed in proper engagement with one or more solar panel frames. This is denoted as the engaged position, and is shown in FIG. 12B. In the engaged position, the first guide 1210A is proximate the lowest point on the ramp 1211A, the second guide 1210B is proximate the lowest point on the ramp 1211B, and the top of the channel portion 1206 acts as a stop to prevent the top portion 1208 from moving downward. The surfaces proximate the lowest points of the ramps 1211A, 1211B are generally flat so that the top portion 1208 cannot rotate to a lower position relative to the channel portion 1206. In the engaged position, the top portion 1208 is held in place by the fastener 1218, with the gripping ridges 1216 providing an anti-rotation force to the head 1236 of the fastener 1218 to help hold it in place. Figure 19

[0261] In the engaged position, when the bottom surface of the top portion 1208 contacts and is supported by the top surface of the channel body 1221, the top portion 1208 is supported at a proper engagement height above the base 1202 and the mounting surface. This determines the fixed height and rotational orientation of the top portion 1208 above the base 1202. In the engaged position, the mounting lips 1214A, 1214B extend outward in a direction that is perpendicular to the direction in which the base wings 1203A, 1203B extend outward from the base 1202.

[0262] ​The vertical orientation between the mounting lips 1214A, 1214B and the base wings 1203A, 1203B enables the mounting lips 1214A, 1214B to engage the outer lips or cavities of preferably one or two, and conceivably up to four, solar panel frames, while the base wings 1203A, 1203B engage the flanges of the mounting structure. It is also conceivable that the mounting structure can have flanges or other engagement portions oriented in different manners, such that the relationship between the base wings 1203A, 1203B and the mounting lips 1214A, 1214B can be oriented in other directions than those shown in the figures. This can be desirable for shared-rail mounting structures or for rail-less mounting structures.

[0263] In installing the clamp 1200, the clamp 1200 is typically pre-assembled by the manufacturer in the engaged position and shipped to the installation site ready for installation. By orienting the assembled clamp 1200 such that the base wings 1203 engage the mounting structure flanges, the installer is able to insert the base 1202 into the open channel of the mounting structure. In this stable position within the rail R or mounting structure, the clamp 1200 can be slid along the slot or channel of the rail R or mounting structure. The installer then slides the clamp 1200 to its desired position within the rail R or mounting structure, with the clamp 1200 secured in place against the rail R. The installer can then rock or rotate the desired panel module, which contains one of the solar panel frames discussed above, using the solar panel frame 202 from Figure 2 The rocking performed engages the outer lip 208 with one of the mounting lips 1214A, 1214B on the rotating clamp 1200, with the base 1202 supported by the rail R or mounting features. As discussed above, the installation can also be performed by sliding the clamp 1200 along the rail R or mounting structure to a position where the solar panel frame 202 is already in place. At this position, one mounting lip 1214A can engage the outer lip 208. The second solar panel frame 202 can then be attached by using the rocking and rotating method described previously.

[0264] To remove the solar panel module, loosen fastener 1218. As fastener 1218 is loosened, spring force pushes the top portion 1208 upward. When the top portion 1208 is pushed upward by spring 1220, the gripping ridge 1216 engages the serrations on the head 1236 of fastener 1218, facilitating synchronous rotation of the top portion 1208 and fastener 1218. Although not shown, spring 1220 may be a torsion spring. Torsion spring 1220 additionally causes the top portion 1208 to rotate in the opposite direction. This rotation occurs due to the engagement between guides 1210A, 1210B and ramps 1211A, 1211B. Guides 1210A, 1210B rotate about channel portion 1206 due to their contact with ramps 1210A, 1210B. This disengages the mounting lips 1214A and 1214B from the outer lip 208 of the solar panel frame 202, thereby allowing the solar panel module to be removed from the clamp 1200.

[0265] When the top portion 1208 has been displaced relative to the channel portion 1206 so that the solar panel module can be removed from the clamp 1200, the clamp 1200 is considered to be in the disengaged position. This is in Figure 20 As shown in the diagram. In the disengaged position, the mounting lips 1214A, 1214B extend in a direction generally parallel to the base wings 1203A, 1203B. This transition between the engaged and disengaged positions allows for maintenance of one or more solar panel modules in the array. To access an individual solar panel module, clamps positioned along one side of the module can loosen their respective fasteners 1218, causing clamp 1200 to transition from the engaged position to the disengaged position. The individual solar panel module can then be pulled out of the solar panel array, as one side of the module is no longer clamped in place. To replace a solar panel module within the array, the frame 202 can be rocked and rotated into position against clamps 1200 that are still in the engaged position, opposite to those clamps 1200 that have transitioned to the disengaged position. When the solar panel module is in the appropriate position against the track R or the mounting structure, the loosened fasteners 1218 can be tightened again and the disengaged clamps can be moved to their engagement positions, thereby engaging the solar panel frame 1210.

[0266] refer to Figures 22-33BThis illustrates another embodiment of the rotary mounting clamp 2200. The clamp 2200 includes a top portion 2202, a middle portion 2204, and a base 2206. The top portion 2202, the middle portion 2204, and the base 2206 are aligned along a common axis A22. Fasteners 2208 are used to secure the top portion 2202, the middle portion 2204, and the base 2206 together, and fasteners 2208 are also aligned along the common axis A22. The connections between fasteners 2208 and other elements of the clamp 220 will be discussed in more detail below.

[0267] like Figures 22-26 As shown, the top portion 2202 includes a body 2210, which is generally shaped with a trapezoidal prism-shaped cross-section in one direction and a rectangular cross-section in another direction. The body 2210 includes two vertical sidewalls 2211A, 2211B and two angled sidewalls 2213A, 2213B. The angled sidewalls 2213A, 2213B extend outward by a distance equal to or exceeding the characteristics of both the intermediate portion 2204 and the base 2206. Mounting lips 22012A, 22012B extend from the top of the body 2210. The mounting lips 22012A, 22012B extend outward from the vertical sidewalls 2211A, 2211B in a direction opposite to the common axis A22 perpendicular to the clamp 2200. Like the other mounting lips discussed so far, the mounting lips 22012A, 2202B are configured to engage corresponding lips and cavities on the solar panel frame.

[0268] Along the top surface of the body 2210 is a slot 2214 that extends perpendicular to the common axis A2 and parallel to the mounting lips 22012A, 22012B. In the central portion of the body 2210, a notch 2216 extends somewhat partially into the body 2210 along the slot. Within the notch 2216 is a hole 2218 that extends through the body 2210 for receiving the fastener 2208 therein. The hole 2218 can be threaded to facilitate engagement with the fastener 2208, or the hole 2218 can be unthreaded and a clearance hole to enable some rotation of the top portion 2202 relative to the base 2206 to enable the clamp 2200 to be properly installed to the first module frame 102, and then the second module frame 102 subsequently installed to the clamp 2200. The installation will be discussed in more detail below. Such rotation can facilitate installation of the clamp 2200, which will be discussed in more detail below. The body 2210 also defines a hollow 2220 that extends from the bottom surface into the body 2210. The hollow 2220 is only accessible from the bottom surface and is configured to accept the mating walls 22324A, 22324B as part of the middle portion 2204 and the channel portion 2242 as part of the base 2206. Such engagement facilitates the connection between the top portion 2202, the middle portion 2204, and the base 2206.

[0269] As Figure 22 , 23 and 27-29, the middle portion 2204 includes a body 2222. The body 2222 defines alignment flanges 2224A, 2224B and clamp support wings 2226A, 2226B. The alignment flanges 2224A, 2224B extend from opposite sides of the body 2222, and the clamp support wings 2226A, 2226B extend from the other two sides of the body 2222 that are also opposite each other. The alignment flanges 2224A, 2224B include flat portions 2228A, 2228B that extend away from the body 2222, and terminate in tapered portions 2230A, 2230B as they extend away from the body 2222. The alignment flanges 2224A, 2224B are used to arrange the clamp 2200 inside the track R, which will be discussed in more detail below. The clamp support wings 2226A, 2226B have one elongated edge and one angled edge that extends in the direction of one of the alignment flanges 2224A, 2224B. The clamp support wings 2226A, 2226B are configured to help support the clamp 2200 when it is placed inside the track R, which will also be discussed below.

[0270] The alignment flanges 2224A, 2224B and the clamp support wings 2226A, 2226B at least partially define an opening 2232 extending through the body 2222. The opening 2232 is shaped to receive the passage portion 2242 of the base 2206 therethrough. Features of the middle portion 2204, such as the mating walls 2234A, 2234B, are arranged to prevent the passage portion 2242 and the base 2206 from rotating when the passage portion 2242 is received through the opening 2232 and the fasteners 2208 are received through the holes 2244 in the base 2206. As shown in the figures, the opening 2232 is rectangular, but other shapes can be used so long as they can receive the passage portion 2242 and prevent the passage portion from rotating. The mating walls 2234A, 2234B also define the opening 2232. The mating walls 2234A, 2234B extend vertically upward from the body 2222 perpendicular to the top surfaces of the alignment flanges 2224A, 2224B and the clamp support wings 2226A, 2226B. The mating walls 2234A, 2234B are configured to be received within the hollow 2220 of the top portion 2210 to connect the middle portion 2204 to the top portion 2210. As shown in the figures, the mating walls 2234A, 2234B are C-shaped, with the mating wall 2234A appearing as a positive C-shape and the mating wall 2234B appearing as a negative C-shape. However, the mating walls 2234A, 2234B can take other shapes so long as they can be engaged within the hollow 2220 of the top portion 2202. A portion of each mating wall 2234A, 2234B extends along the length of its respective clamp support wing 2226A, 2226B, and two other portions partially extend along the lengths of the opposing alignment flanges 2224A, 2224B.

[0271] As Figure 22 , 23As shown in Figures 30 and 31, the base 22006 includes a body 2236. Base wings 2238A and 2238B extend from opposite sides of the body 2236. The ends of the base wings 2238A and 2238B define slots 2240A and 2240B that extend along the length of the base wings 2238A and 2238B and are configured to partially engage with the track R to further securely hold the rotary clamp 2200 within the track R. Examples of these portions may be corresponding slots G or channels located within the track R, such that the base 2206 can function as a channel nut within the track R. Engaging ridges 2241A and 2241B are located at a central position within the slots 2240A and 2240B. As shown in the figure, the ridges 2241A and 2241B are arranged in pairs, with the first pair of 2241A (identified by a single reference numeral) located in the first slot 2240A and the second pair of 2241B (identified by a single reference numeral) located in the second slot 2240B. The ridges 2241A and 2241B form high points within their respective channels 2240A and 2240B, causing the channels 2240A and 2240B to be non-flat and curved downwards along their length from the ridges 2241A and 2241B. This allows the base wings 2238A and 2238B to rock within the slot G of the track R, thereby providing a degree of rotation for the clamp 2200. This rocking motion enables the clamp 2200 to be mounted, which will be discussed below. The channel portion 2242 extends upwards from the base wings 2238A and 2238B. The channel portion defines a hole 2244, which is configured to receive a fastener 2208 to connect the top portion 2202 to the base 2206. The hole 2244 may be threaded to further secure the fastener 2208.

[0272] like Figures 32-33B As shown, the installation of clamp 2200 will now be described. Clamp 2200 can be installed in several ways. One method is to align clamp 2200 with the end of track R. Track R defines a groove G and a support surface S along its opposing inner sides. At the end of track R, base wings 2238A and 2238B are arranged within groove G, and clamp support wings 2226A and 2226B are arranged on top of the support surface S. This arrangement... Figure 32 As shown in the diagram. Thereafter, the clamp 2200 can slide along the track R to its desired position. At this desired position, the first solar panel frames 102, 202, 302, 402, 11402, and 11602 are either placed on the track or have already been placed on the track (as shown in the diagram). Figure 33AThe clamp 2200 can then be further slid along the rail R and rocked upward so that the first mounting lip 2212A is angled upward, enabling it to be placed over the outer lip 108, 208, 308, 408 of the frame 102, 202, 302, 402, 11402, 11602 to engage with the clamp cavity 112, 212, 312, 412 of the frame 102, 202, 302, 402, 11402, 11602. This is shown in Figure 33A As noted above, the placement of the engagement ridges 2241A, 2241B within the channels 2238A, 2238B facilitates rocking of the clamp 2200 to mount the clamp 2200 to the module frame 102, 202, 302, 402. One way to achieve this is to form a space between the channels 2238A, 2238B and the top portion of the slot G on either side of the engagement ridges 2241A, 2241B. This space allows the base wings 2238A, 2238B to rock within the slot G, which enables the top portion 2202 of the clamp 2200 to tilt so that the first mounting lip 2212A can be mounted within the clamp cavity 112, 212, 312, 412. As noted above, the holes 2218 in the top portion 2202 can be free of threads for the fasteners 2208 so that the top portion 2202 can be tilted upward to enable the mounting lip 2212A to more easily engage with the clamp cavity 112, 212, 312, 412.

[0273] When the mounting lip 2212A is secured to the clamp cavity 112, 212, 312, 412, the second frame 102, 202, 302, 402, 11402, 11602 can be rotated into position by sliding the second frame 102, 202, 302, 402 along the rail R in an angled orientation so that the outer lip 108, 208, 308, 408, 11408, 11608 extends below the second mounting lip 2212B. In this way, when the second module is rotated downward to fully engage the rail R and the second frame 102, 202, 302, 402, 11402, 11602 is rotated from the angled orientation to a flat orientation on the rail R, the clamp cavity 112, 212, 312, 412, 11412, 11712 can engage with the second mounting lip 2212B. This rotation is shown in Figure 33BThe height of the mounting lips 2212A, 2212B above the top of the track R is defined by the assembled dimensions of the clamp 2200 when the fasteners 2208 are tightened with the top portion 2202 secured to the base 2206 such that the hollow 2220 contacts the top of the channel portion 2242, thereby defining the distance of the mounting lips 2212A, 2212B above the base wings 2238A, 2238B and their position within the slot G of the track R. The height of the mounting lips 2212A, 2212B above the top of the track R is dimensioned such that when the second frame 102, 202, 302, 402, 11402, 11602 is rotated from an inclined orientation to a flat orientation on the track R, the outer lips 108, 208, 308, 408, 11408, 11608 exert an upward force on the mounting lips 2212A, 2212B, thereby effectively creating a clamping force on the first and second frames 102, 202, 302, 402, 11402, 11602 between the top portion 2202 of the clamp 2200 and the top surface of the track R. The clamping force between the mounting lips 2212A, 2212B and the frame 102, 202, 302, 402 acts perpendicular to the direction of movement of the clamp 2200 within the track R, such that when the clamp 2200 is mounted to the frame 112, 212, 312, 412, the clamp 2200 is secured in its proper position within the track R. Only the placement of the clamp into the track R is required to perform the installation of the modular frame 102, 202, 302, 402.

[0274] A second method of mounting the clamp 2200 to the track R and frame 102, 202, 302, 402 is similar to the first method, but this method involves sliding the clamp into the track R perpendicular to the above-described sliding movement of the clamp 2200. The tapered ends 2230A, 2230B of the alignment flanges 2224A, 2224B enable the clamp 2200 to be entered into the track R from above. In this manner, the alignment flanges 2224A, 2224B are angled downwardly into the track R and then into the space between the slot G and the support surface S. Thereafter, the clamp 2200 can be rotated within the track R such that the support wings 2226A, 2226B and the base wings 2238 are supported by the support surface S and the slot G of the track, respectively. Once the clamp 2200 is placed within the track R, the above-described installation method can continue.

[0275] To disengage the frame 102, 202, 302, 402 from the clamp 2200, the fasteners 2208 are loosened such that the top portion 2202 can be loosened or removed, which disengages the mounting lips 2212A, 2212B from their respective clamp cavities 112, 212, 312, 412, such that the frame 102, 202, 302, 402 can be removed.

[0276] In some cases, the clamp 2200 can be pre-assembled prior to use, meaning that the fasteners 2208 are arranged snugly against the top portion 2202. In such cases, the clamp 2200 is considered a tool-less clamp, meaning that no tools are needed to attach the clamp 2200 to the rail R and associated frame 102, 202, 302, 402. In other cases, the fasteners 2208 can not be tightened completely against the top portion 2202 and the base.

[0277] Referring now to Figures 34-40 , an installation clamp 3400 is shown. The installation clamp 3400 is a lever clamp 3400 and can be so referred to. The lever clamp 3400 includes a base 3402 and an installation lever 3404 that engages with and connects two solar panel frames 202 to the lever clamp 3400, as shown in Figure 38 and 39 . Fasteners 3403 facilitate the connection of the base 3402 and the installation lever 3404 so that the two solar panel frames can be engaged and connected to the lever clamp 3400. Although not shown, the lever clamp 3400 can also include a spring that fits between the installation lever 3404 and the base 3402 to push the installation lever 3404 upwardly relative to the base 3402, as will become apparent below.

[0278] As shown in Figures 34-37 , the base 3402 includes a first support flange 3406 for supporting a first solar panel frame and a second support flange 3408 for supporting a second solar panel frame. The support flanges 3406, 3408 extend in generally opposite directions. A central portion 3410 connects the two support flanges 3406, 3408. The central portion 3410 can include a lower connector 3412 that extends across substantially the same plane as the two support flanges 3406, 3408, and an upper connector 3414 that has a U-shape that encloses the lower connector 3412. The lower connector 3412 has a hole 3416 and the upper connector 3414 has a hole 3418. The two holes 3416, 3418 are aligned to receive an installation fastener therethrough in order to connect the lever clamp 3400 to a support structure, which is shown and described in connection with Figures 90-93 . One or both of the holes 3416, 3418 can be clearance holes to enable some movement of the fastener when placed within the holes 3416, 3418 to facilitate installation of the lever clamp 3400. As shown in Figure 37 , the upper connector 3414 includes a hole 3417 that is used to accept another fastener 3403 to secure the installation lever 3404 to the base 3402 in the engaged configuration of the lever clamp 3400.

[0279] The upper connector 3414 defines a first mounting lip 3420 at an end thereof. The first mounting lip 3420 opposes the first support flange 3406 to define a first mounting space 3415 therebetween. The first mounting lip 3420 engages the outer lip 208 of the solar panel frame 102, and the support flange 3406 supports the base 1212. The first mounting lip 3420 is shaped so that it fits around the end of the outer lip 3423 3422. The first mounting lip 3420 can be resilient to create an audible and tactile engagement with the outer lip 208. The first mounting lip 3420 is also shaped to hold the base 1212 of the solar panel 1210 generally flat against the first support flange 3406. A generally J-shaped angled flange 3423 3422 extends from the first support flange 3406. The angled flange 3423 3422 includes an edge 3423 that engages the base 204 of the solar panel frame 202 to further help hold the solar panel frame 202 in place. The angled flange 3423 3422 can also be resilient and provide a further tactile or audible indication of a successful connection between the solar panel frame 102 and the lever clamp 3400. The angled flange 3423 3422 can also be curved so as to define a space 3424 below the base 3406. As shown, only the first surface 3406 includes the angled flange 3423 3422, but another angled flange can extend from the second surface 3408 to provide a guide for the installation of the second panel frame.

[0280] The upper connector 3414 defines a socket 3426 proximate the first mounting lip 3420. The socket 3426 receives a corresponding ball 2228 at an end of the mounting lever 3404. The joint formed by the ball 2228 and the socket 3426 enables the mounting lever 3404 to rotate about the upper connector 3420. It is contemplated that other joints can be used in a similar manner to the ball and socket joint described herein. The mounting lever 3404 also defines a hole 2230 for receiving the fastener 3403. The hole 2230 is aligned with the hole 3417 to further facilitate the connection between the mounting lever 3404 and the base 3402. The mounting lever 3404 defines a second mounting lip 2232 that engages the outer lip 208 in the same manner as the first mounting lip 3420. The second mounting lip 2232 opposes the second support flange 3408 to define a second mounting space 2233. Rotation of the mounting lever 2104 about the base 3402 via the action of the ball 2228 and the socket 3426 means that the mounting lever 2104 can be displaced between a disengaged state in which the second mounting lip 2232 is rotated away from the outer lip 108, as shown in Figure 22, and an engaged state in which the second mounting lip 2232 is rotated towards the outer lip 108, as shown in Figure 21. Figure 39As shown in FIG. 34, in the engaged state, the second mounting lip 2232 opposes the second surface 3408 to engage the outer lip 108, as shown in FIG. 34. Figure 38 Rotation of the mounting lever 3404 means that the hole 2230 in the mounting lever 3404 must be elongated to accept the fastener 3403 which would otherwise be obstructed. Thus, the hole 2230 is larger than the holes 3416, 3417 in the base 3402.

[0281] Tightening and loosening of the fastener 3403 restricts or allows such rotation of the mounting lever 3404, and can facilitate engagement of the second mounting lip 2232 with the outer lip 1222. In other words, when the fastener 3403 is tightened within the holes 3417, 2230, the mounting lever 3404 is pushed downward and secured in the engaged state. When the fastener 3403 is loosened, it can be partially pulled out of the holes 3417, 2230 so as to raise the head of the fastener 3403 above the mounting lever 3404, thereby allowing the mounting lever 3404 to move to the disengaged state.

[0282] The method of installation of the lever clamp 3400 involves attaching the pre-assembled lever clamp 3400 in the engaged state to a mounting structure, such as a roof attachment, using a fastener and mounting structure, neither of which are shown but will be discussed in more detail in the support structure and other mounting clamp sections. The entire mounting assembly is connected to the solar panel frame 202 by inserting the first mounting lip 3420 into the clamp cavity 212 of the frame 202, rotating the clamp assembly 3400 downward relative to the frame 202 so that the first support flange 3406 moves toward the panel base 206 until the angled flange 3422 wraps around the inside of the base 206 and the edge 3423 snaps onto the base flange 230. This connects the lever clamp 3400 to the solar panel frame 202. For the first panel in a series, row, or column of panels, the entire mounting assembly can be installed to both panel frames 202 on opposite sides of the solar panel module. The solar panel module with the mounting assembly attached can then be placed in the desired location on the roof or other mounting surface, and the mounting structure or roof attachment (not shown) can be secured to the roof or other mounting surface.

[0283] For subsequent panels in a row, a column, or series, installation preparation is performed by connecting two mounting assemblies (or three, if additional support is required for the environmental loads) to the single first panel frame in the same manner as above, and installation is performed by placing the second opposing panel frame base at an angle onto the second support flange 3408, moving the panel toward the lever clamp 3400, inserting the mounting lip 2232 into the clamp cavity 212, and then rotating the solar panel module downward until the mounting assemblies on the opposing panel frame fall onto the mounting surface and the base 206 contacts the second support flange 3408 with the outer lip 208 properly seated and secured beneath the mounting lip 2232. This process is repeated until installation of all desired panels in a row, a column, or a series is complete.

[0284] During the useful life of a solar array, situations can arise that require replacement of individual panels within the array. The lever clamp 3400 facilitates removal of individual modules within the array without disturbing adjacent or other modules and requires only disengagement of the lever clamp 3400 on one side of the panel to be removed. To remove an individual panel, the fasteners 2205 of the lever clamp 3400 on one side of the panel to be removed are loosened until the mounting lever 3404 can be rotated about the ball 3426 and socket 2228 joint to a disengaged position. The panel can then be tilted away from the disengaged clamp 3400 and rotated away from the opposing lever clamp 3400 by withdrawing the base 206 from the support surface 3406 until the outer lip 208 disengages the clamping force of the mounting lip 3420, and the panel is removed. A replacement panel can then be installed in place by placing the solar panel frame 202 onto the first support flange 3406, rotating the panel downward until the opposing frame falls onto the second support surface 3408, and tightening the fasteners 3403 until the mounting lip 2232 is secured in the mounting cavity 212.

[0285] Reference Figures 40-43Another mounting clamp 4000 is shown in FIGS. 42 and 43. The mounting clamp 4000 is a sliding clamp and can be so referred to. The sliding clamp 4000 includes a base 4002 and two blocks 4004A, 4004B that are slidable within the base 4002. The base 4002 includes a divider 4006 to separate the blocks 4004A, 4004B within the base 4002. The base 4002 defines holes 4008A, 4008B, with the holes 4008A, 4008B being disposed on opposite sides of the divider 4006, respectively. Each block 4004A, 4004B has holes 4010A, 4010B that correspond to the holes 4008A, 4008B in the base 4002. The hole 4010A is generally aligned with the hole 4008A, and the hole 4010B is generally aligned with the hole 4008B. The aligned holes 4008A, 4010A, 4008B, 4010B allow fasteners 4012A, 4012B to extend through the pair of aligned holes 4008A, 4010A, 4008B, 4010B and connect the blocks 4004A, 4004B to the base 4002 and underlying mounting structure, examples of which are provided in FIGS. 42 and 43. Tightening of the fasteners 4012A, 4012B within the holes 4008A, 4008B, 4010A, 4010B secures the blocks 4004A, 4004B to the base 4002, and loosening of the fasteners 4012A, 4012B within the holes 4008A, 4008B, 4010A, 4010B allows the blocks 4004A, 4004B to slide within the base 4002. Because the blocks 4004A, 4004B are designed to slide within the base 4002, the holes 4010A, 4010B defined in the blocks 4004A, 4004B are elongated and wider than the holes 4008A, 4008B defined by the base 4002. This enables the fasteners 4012A, 4012B to be loosened or removed within the holes 4008A, 4008B, which allows the blocks 4004A, 4004B to slide within the base 4002, while keeping the fasteners 4012A, 4012B within the holes 4010A, 4010B. When the blocks 4004A, 4004B are in their desired position, the fasteners 4012A, 4012B can again be tightened within the holes 4008A, 4008B, thereby again securing the blocks 4004A, 4004B to the base 4002.

[0286] Blocks 4004A and 4004B each have corresponding mounting lips 4014A and 4014B, which are used to engage with the solar panel frame to be mounted to the sliding clamp 4000. Mounting lips 4014A and 4014B are designed to engage with an outer lip and mounting cavity, as discussed above in conjunction with different embodiments of the solar panel frame. It should also be understood that mounting lips 4014A and 4014B can be used to mount additional solar panel frames or other accessories not disclosed in this application. Mounting lips 4014A and 4014B may also have teeth on their underside to facilitate engagement with the mounted panel frame 1210. Sliding of blocks 4004A and 4004B causes blocks 4004A and 4004B to move between an engaged state, in which the solar panel frame can be mounted to the sliding clamp 4000, and in the disengaged state, in which the solar panel frame can be removed from the sliding clamp 4000 or otherwise disengaged. The joined state is shown in Figure 42, and the partially disengaged joined state is shown in... Figure 43 As shown in the diagram. The solar panel frame can be installed onto blocks 4004A and 4004B by snapping or rotating the frame relative to blocks 4004A and 4004B into place while they are already in the engaged state, or by placing the frame into place and then sliding blocks 4004A and 4004B into the engaged state while they are in the disengaged state. The frame is removed by sliding blocks 4004A and 4004B from the engaged state to the disengaged state. In some embodiments, springs 4016A and 4016B can be applied to the ends of blocks 4004A and 4004B opposite to the ends having mounting lips 4014A and 4014B. Springs 4016A and 4016B can bias blocks 4004A and 4004B toward the engaged state. The sliding clamp 4000 can be incorporated into an installation system similar to the installation systems described above regarding the lever clamp 3400, rotary clamp 1200, lever clamp 3400, etc., and can include associated installation and assembly methods.

[0287] refer to Figures 44-47FIG. 44 shows another mounting clip 4400. The mounting clip 4400 can be referred to as a clip-ramp piece mounting assembly 4400. This assembly 4400 can be used in conjunction with the solar panel module 402 due to the provision of the curved central portion 406. The assembly contains a clip 4402 and a ramp piece 4404, both of which are used to mount and secure the solar panel frame 404 within the assembly 4400. Both features have aligned holes for receiving fasteners (only the holes 4405 of the ramp piece 4404 are shown) that mount the clip 4402, the ramp piece 4404, and the rail R together to secure the assembly 4400. The clip 4402 contains a body 4406, which is shown as being generally quadrilateral, but other body shapes can be used. The body 4406 contains a first mounting lip 4408A and a second mounting lip 4408B that extend from opposite sides of the body 4406. The mounting lips 4408A, 4408B engage the solar panel frame in a similar manner as discussed above in connection with the clip 4200. Figure 9 and 10 The ramp piece 4404 facilitates engagement of the solar panel frame with the clip 4402.

[0288] The ramp piece 4404 contains a central portion 4410 that is generally flat and has a rectangular shape with the holes 4405 defined therein. Two side cavities are also shown. Support portions 4412A, 4412B extend in opposite directions from the central portion 4410. The support portions 4412A, 4412B are located a distance below the central portion 4410. The support portions 4412A, 4412B have flat surfaces to support the flat bottom portions of the base 404 and the outer lips 408 of the solar panel frame 402, and have rounded end portions 4414A, 4414B to support the rounded central portion 406 of the frame 402. Peak surfaces 4416A, 4416B extend from the rounded end portions 4414A, 4414B, which are also generally flat, to support the flanges 430 of the panels 1510. Ramp surfaces 4418A, 4418B extend from the peak surfaces 4416A, 4416B, which are angled downwardly relative to the flange surfaces 4416A, 2016B and the rail R. The ramp surfaces 4418A, 4418B terminate near the upper surface of the rail, but contain extensions 4420A1, 4420A2, 3220B1, 4420B2 that extend along opposite sides of the rail R, as shown in FIGS. 44 and 45. These extensions define a gap G1 therebetween that is used to align the ramp piece 4404 on the rail R. Figure 31 and 35

[0289] ​The arrangement of the ramp piece 4404 and the circular center portion 406 of the solar panel frame 402 relative to the rail R and the clamp 4402 facilitates installation of the solar panel frame 402 to the clamp 4402. It also facilitates holding the frame 402 secured within the ramp piece 4404. In installing a solar panel module, the panel frame 402 is tilted relative to the rail R or other mounting structure with one panel frame 402 on the rail R and the opposite panel frame 402 held by an installer at an elevated position for maneuvering the panel into the system. The installer moves the opposite panel toward the clamp 4402 so that the frame 402 approaches the ramp 4418A or 4418B and the bottom portion of the outer lip 408 slides up along one of the ramp surfaces 4418A. As the frame 402 continues to move toward the clamp assembly 4400, the frame 402 passes over the peak surface 4416A, 4416B and into the space extending above the support surface 4412A, 4412B and below the mounting lip 4408A, 4408B. The movement of the frame 402 over the different surfaces 4418A, 4416A, 4414A effectively rotates the panel frame 402 so that the outer lip 408 is below the mounting lip 4408A. The installer then lowers the opposite solar panel frame 402 onto the mounting structure or rail R, thereby rotating the solar panel module so that the outer lip 408 continues to rotate and comes into contact with and clamping engagement with the mounting lip 4408A. The reverse actions can be taken to remove the solar panel frame 402. When the solar panel frame 402 is within the clamp-ramp piece installation assembly 4400, the circular surface 416 of the frame 402 acts as a stop against the circular end 4414A of the ramp piece 4404. This facilitates further securing the panel frame 402 within the ramp piece 4404 below the clamp 4402.

[0290] REFERENCE Figures 48-52Another mounting clip 4800 is shown in FIG. 48. The mounting clip includes a base 4802 and a top portion 4804 disposed partially over the base 4802. The base 4802 includes a first support flange 4806 for supporting a first solar panel frame and a second support flange 4808 for supporting a second solar panel frame. The support flanges 4806, 4808 extend in generally opposite directions. A central portion 4810 connects the two support flanges 4806, 4808. Side walls 4807, 4809 extend from the base 4802 to separate the central portion 4810 from the support flanges 4806, 4808. The side wall 4807 extends a first distance proximate the support flange 4806 and the side wall 4809 extends a second distance proximate the support flange 4808. As shown in the figure, the side wall 4807 extends a greater distance than the side wall 4809. The two support flanges 4806, 4808 can have different features to facilitate engagement with their respective solar panel frames. As shown in the figure, the support flange 4806 includes a curved surface to facilitate rotation of the solar panel frame relative to the mounting clip 4800 when the solar panel frame is mounted to the clip 4800. The support flange 4808 includes a rough surface to grip the solar panel frame when the solar panel frame is engaged with the mounting clip 4800.

[0291] The top portion 4804 is disposed partially over the base 4802 and includes a first clamping flange 4812 that extends in one direction and is opposite the first support flange 4806. The top portion 4804 also includes a second clamping flange 4814 that extends opposite the first clamping flange 4812. The second clamping flange 4814 is opposite the second support flange 4808. The clamping flanges 4812, 4814 can include features to connect or engage to a solar panel frame to be engaged with the clamp 4800, such as engagement teeth 4813 that are embedded in a solar panel frame when the solar panel frame is installed. The first support flange 4806 and the first clamping flange 4812 define a first mounting space 4816 therebetween, and the second support flange 4808 and the second clamping flange 4814 define a second mounting space 4818 therebetween. The mounting spaces 4816, 4818 are arranged to receive a solar panel frame therebetween and secure the solar panel frame to the mounting clamp 4800 for installation in an array or other solar panel system. The top portion also includes a sidewall 4820 that extends downward from the first clamping flange 4812 and a sidewall 4822 that extends downward from the second clamping flange 4814, where both sidewalls 4820, 4822 extend in a direction toward the base 4802. As shown in the figures, the sidewall 4820 extends a greater distance in the direction toward the base 4802 than the sidewall 4822. The sidewall 4820 is also adjacent to the sidewall 4807. The sidewalls 4820, 4822 are connected by bridge portions 4824, 4826. The bridge portion 4824 extends from the end of the sidewalls 4822, 4822 and to the midpoint of the sidewall 4820. The bridge portion 4826 extends between the sidewalls 4820, 4822 proximate the clamping flanges 4812, 4814. The bridge portions 4824, 4826 extend mostly over the central portion 4810 of the base 4802 in the direction of the support flanges 4806, 4808. However, the top portion 4804 only extends over a portion of the center of the base 4802 in a direction orthogonal to the support flanges 4806, 4808. This leaves a portion of the central portion 4810 exposed.

[0292] The exposed portion of the center portion 4810 defines a mounting hole 4828 that connects to a mounting fastener, which will be described in greater detail below. The center portion 4810 also defines a connection hole 4830 adjacent the mounting hole 4828. The bridge portions 4824, 4826 also define respective connection holes 4832, 4834. The connection holes 4830, 4832, 4834 are aligned and arranged to receive a connection fastener 4836 therethrough. The connection fastener 4836 connects the base 4802 to the top portion 4804. The connection fastener 4836 includes a threaded bottom portion 4838 that corresponds to threads in the connection hole 4830 to secure the connection fastener 4836 to the base 4802. The other connection holes 4832, 4834 can be clearance holes, or the connection hole 4832 can also have threads that correspond to the threaded bottom portion 4838 of the connection fastener 4836. A spring 4840 can be disposed around the top portion connection fastener 4836. As shown in the figure, additional side walls 4842, 4844 can extend from the center portion 4810 in a direction toward the top portion 4804. The side wall 4842 extends so as to overlap the side wall 4820, and the side wall 4844 extends a shorter distance than the distance defined by the side wall 4842. These side walls 4842, 4844 can visually and physically define the portion of the center portion 4810 that defines the mounting hole 4828 and the connection hole 4830.

[0293] Other Components

[0294] Reference Figures 53-6 1, a hidden end clamp 5300 for mounting a solar panel frame to an end of a rail R is shown. The hidden end clamp 5300 includes a rail engaging portion 5302, a frame engaging portion 5304, and a fastener 5306 for connecting the rail engaging portion 5302 and the frame engaging portion 5304 together within the rail R.

[0295] As Figures 53-5 9, the rail engaging portion 5302 includes a first side wall 5308 and a second side wall 5310. The first side wall 5308 has a first rail flange 5312 extending from a top surface and curved with respect to the first side wall 5308. The second side wall 5310 has a second rail flange 5314 extending from a top surface and curved with respect to the second side wall 5310. As Figure 55As shown in FIG. 53, the rail flanges 5312, 5314 are arranged to be received in the slots RG defined in the two sides of the rail R. The engagement between the rail flanges 5312, 5314 and the slots G support the hidden end clamp 5300 within the rail R. The center piece 5316 extends between the first and second side walls 5308, 5310, connecting the two side walls 5308, 5310 and defining a space 4119 that receives a portion of the frame engagement portion 5304. The turnouts 5318 extend from the top surface of the center piece 5316 and are curved relative to the center piece 5316. The turnouts 5318 can contact a portion of the frame engagement portion 5304 to provide some support thereto. The center piece 5316 can also include angled or ribbed portions that connect to the side walls 5308, 5310 at an angle less than 90 degrees. The center piece 5316 also defines a hole 5320 for receiving a fastener 5306. The hole 5320 and the fastener 5306 include corresponding threads. In other embodiments, other methods of connection known to those of ordinary skill in the art can be used.

[0296] As Figures 53-57As shown in FIGS. 60 and 61, the rail R defines a slot RG and a support surface SS along opposite inner sides. The frame engagement portion 5304 includes a base 5322 and a body 5324 extending from the base 5322. The base 5322 includes side portions 5329 that extend beyond the body 5324, which support the first side wall 5308 and the second side wall 5310 of the rail engagement portion 5302. The body 5324 extends from the base 5322 such that it is received for the most part within the space defined by the first side wall 5308, the second side wall 5310, and the center piece 5316. The body 5324 defines an upright, elongated hole 5326 that receives the fastener 5306. The hole 5326 of the body 5324 is aligned with the hole 5320 of the center piece 5316. A frame support panel 5328 extends upwardly from the body 5324, which includes a frame support member 5330 for supporting a solar panel frame 102 thereon. When installed in the rail, the frame support member 5330 can be flush with or slightly above the top surface of the rail R, thereby providing support for the frame. The frame support member 5330 can be below the top surface of the rail R, and the frame support member 5330 can not support the frame as the top surface of the rail supports the frame. The frame support panel 5328 is angled relative to the body 5324 such that the frame support surface 5330 is flush with the top of the rail R. This allows the solar panel frame 202 to be horizontal relative to the rail R. Depending on the angle of the surface on which the rail R is installed or other operating conditions, the frame support panel 5328 can be arranged to define different angles between the solar panel frame 102, 202, 302, 402, 11402, 11602 and the rail R. The frame support panel 5328 also includes a mounting lip 5332 extending upwardly from the frame support surface 5330. The mounting lip 5332 functions the same as the mounting lips previously described in this application.

[0297] The center piece 5316 includes a threaded hole 5320 and can act as a nut that receives the fastener 5306, the upright, elongated hole 5326, the threaded hole 5320, and the fastener 5306 are concentrically aligned along an axis A53. The axis A53 extends along the length of the rail R at a vertically offset angle such that the drive head of the fastener 5306 extends upwardly and can be easily accessed by a driving tool, such as a drill bit or impact wrench, from above the top of the rail R.

[0298] The bottom surfaces of the side walls 5308, 5310 and the top surface of the side portion 5329 are parallel to each other and angled with respect to the axis A53. When the fastener 5306 is tightened, the frame engagement portion 5304 and the rail engagement portion 5302 are brought together, the bottom surfaces of the side walls 5308, 5310 and the top surface of the side portion 5329 slide across each other, the fastener 5306 is able to move by virtue of the elongation of the hole 4126, the first and second rail flanges 5312, 5314 are pushed upwards against the top of the rail slot RG, the side extensions 5331 of the frame support member 5330 are pushed downwards against the support surface SS of the rail R, so the rail engagement portion and the frame engagement portion exert a clamping force on the rail slot RG and the rail support surface SS, and the hidden end clamp 5300 is secured to the rail R. In this way, the hidden end clamp can be installed in the rail and secured to the rail without the frame. This enables the installer to first install the hidden end clamp, and then swing the solar module frame 102, 202, 3092, 402, 11402, 11602 into position by tilting the solar panel, extending the outer lip 108, 208, 308, 408, 11408, 11608 under the mounting lip 5332, and then lowering the module so that the frame rotates and the outer lip exerts an upward force against the mounting lip 5332.

[0299] Alternatively, the solar panel can be placed on the rail R first, and then the hidden end clamp 5300 can be slid along the rail until the mounting lip 5332 extends over the outer lip 108, 208, 308, 408, 11408, 11608 and engages the cavity 112, 212, 312, 412, 11412, 11612. Then, the fastener 4106 can be tightened and the hidden end clamp 5300 is secured to the rail R, while the frame 102, 202, 302, 402, 11402, 11602 is firmly clamped to the rail R.

[0300] Reference Figures 63-66FIG. 19 shows an accessory mount 6200. The accessory mount 6200 can be used to support other features relative to the solar panel frame 102, including but not limited to module-level power electronics, electrical controls, or wire management devices or organizers. The accessory mount 6200 includes a body 6202 with a first plate 6204 and a second plate 6206 between which the solar panel frame 102 can be placed. As shown, the first plate 6204 and the second plate 6206 define an angle of approximately 90 degrees that the solar panel frame 102 fits within. The area of the body 6202 where the first plate 6204 and the second plate 6206 meet is rounded to accommodate the rounded outer lip of the solar panel frame 102. Other shapes can be used to accommodate the shape of other frame panels. The first plate 6204 includes attachment hooks 6208 that extend from the surface of the first plate 6202 to engage with the solar panel frame 102. The attachment hooks 6208 can have pointed tips to make an electrical or grounding connection between the attachment hooks 6208 and the solar panel frame 102. The second plate 6206 includes an attachment lip 6210 that engages with the outer lip 108 of the solar panel frame 102. This engagement can be the same as the engagement already described in this application. Near the attachment lip 6210, the second plate 6206 also defines a handle 6212. The handle 6212 is bent away from the portion of the second plate 6206 that contacts the solar panel frame 102 so that a user can pull the handle to disengage the attachment lip 6210 from the outer lip 108. This action helps to disconnect the accessory mount 6200 from the solar panel frame 102. Although not shown, a handle can also be used in conjunction with the first plate 6204. The second plate 6206 also includes a grounding tooth 6214 that is a pointed tip that electrically connects and / or bonds the solar panel frame 102 and the accessory mount 6200. Although two attachment hooks 6208 and an attachment lip 6210 and one grounding tooth 6214 are shown, it should be understood that different numbers of these features can be defined in the accessory mount.

[0301] Although not shown, it should be understood that the first plate 6204 can include threaded holes or other features for attaching MLPE (photovoltaic system) or other accessories to the accessory mount 6200 and can include a grounding tooth for electrically connecting or bonding the accessory mount 6200 to the accessory. In one preferred embodiment (not shown), the accessory mount can be integrally incorporated into the housing body of the accessory. The accessory mount 6200 can also be arranged in a perpendicular manner to that shown in the figures. In other words, the second plate 6206 can extend parallel to the base 106 of the panel frame 102 used with the accessory mount 6200.

[0302] Reference Figures 67-70FIG. 67 shows a joining cross 6700. The joining cross 6700 is configured to electrically connect two adjacent frames 102, 202, 302, 402, 11402, 11602. The joining cross 6700 includes an elongated body 6702 and two frame receiving sections 6704A, 6704B at opposite ends of the elongated body 6702. The elongated body 6702 includes a first straight portion 6706 and a second straight portion 6708 connected by a bend portion 6710 therebetween. The bend portion 6710 defines an acute angle and is V-shaped. The bend portion 6710 provides flexibility in the lengthwise direction, which helps to resist thermal expansion. However, additional shapes and arrangements can be used as long as the function of the joining cross 6700 is maintained. The bend portion 6710 is located at a central location along the elongated body 6702 at adjacent ends of the straight portions 6706, 6708. The frame receiving sections 6704A, 6704B are located at further ends of the straight portions 6706, 6708 opposite the ends connected to the bend portion 6710.

[0303] Frame receiving section 6704A, 6704B are identical and contain identical features. These features have the same element number in the figures. Only the features of one frame receiving section 6704A will be described herein and it should be understood that the other frame receiving section 6704B has identical features thereon. Frame receiving section 6704A contains a frame engaging portion 6712A that engages with frame 102, 202, 302, 402, 11402, 11602 and a curved bottom wall 6714A that partially wraps around frame 102, 202, 302, 402, 11402, 11602 and then curves away from the frame. Frame engaging portion 6712A contains a cavity side wall 6716A, a lip top wall 6718A, and a lip side wall 6720A. These walls 6716A, 6718A, 6720A together define a lip receiving space 6722A that the lip 108 of frame 108 is held in. To define receiving space 6722A, cavity side wall 6716A, lip top wall 6718A, and lip side wall 6720A form an inverted U shape. In this configuration, cavity side wall 6716A is arranged to fit against outer lip 108, 208, 308, 408, 208, 308, 408 within clamp cavity 112, 212, 312, 412, lip top wall 6718A extends from cavity side wall 6716A over the top of outer lip 108, 208, 308, 408, 208, 308, 408, and lip side wall 6720 extends from lip top wall 6718A along the side of outer lip 108, 208, 308, 408 opposite clamp cavity 112, 212, 312, 412. Lip side wall 6720A is made of a first portion 6721A1 and a second portion 6721A2 with an opening 6716 formed between the first portion and the second portion. Opening 6716 exposes a portion of outer lip 108, 208, 308, 408 when jumper 6700 is connected to frame 102. Curved bottom wall 6714A extends from both portions 6721A1, 6721A2 of lip side wall 6720A and also extends along the entire length of frame receiving section 6704A. Curved bottom wall 6714A first extends in a direction towards frame 112 with a portion of curved bottom wall 6714A wrapping around the bottom of outer lip 108, 208, 308, 408. Then, curved bottom wall 6714A extends in a direction away from outer lip 108, 208, 308, 408.

[0304] Cavity side wall 6716A includes a binding tooth 6726A formed in side wall 6716A and angled in the direction of outward lip 108, 208, 308, 408 so as to contact and penetrate the outer surface of outward lip 108, 208, 308, 408 when binding cross-connector 6700 is applied to frame 102. This creates an electrical connection between frame 102 and binding cross-connector 6700. This can be used to ground the solar panel frame 102 in the assembly. Frame engagement portion 6712A also includes an everted panel 6728A extending from lip top wall 6718A over opening 6716A. Everted panel 6728A extends straight outward from lip top wall 6718A in a direction perpendicular to cavity side wall 6716A and lip side wall 6720A. It is contemplated that everted panel 6728A can extend from lip top wall 6718A in other non-perpendicular directions.

[0305] To connect binding cross-connector 6700 to frame 102, a downward force is applied on everted panel 6728A so that the end of the solar panel frame is somewhere within lip receiving space 6724A so as to slide cavity side wall 6718A, lip top wall 6720A, and lip side wall 6722A into place around outward lip 108, 208, 308, 408. Then, the outward lip 108, 208, 308, 408 of the second frame 102 is slid into place within the second lip receiving space 6724B on second frame receiving section 6704B. Binding cross-connector 6700 is made of metal or another electrically conductive material to create an electrical connection between the two frames 102.

[0306] Reference Figure 71 and 72wire organizer 7100. The wire organizer 7100 includes a hollow body 7102 for storing, routing, and organizing wire W relative to the solar panel frame 102. The hollow body 7102 defines a cavity 7104 in which the wire W is stored. The cavity 7104 can be sized to accommodate and route multiple wires, including home run wires and wires that run through the photovoltaic panel array. The hollow body 7102 further defines a slot 7106 for placing wire into the cavity 7104. The hollow body 7102 defines a notch 7108 at a diagonal position from the slot 7106 for receiving the base 206 of the solar panel frame 202. In some embodiments, a flange (not shown) can extend from the base 206 to fit within the notch 7108. The hollow body 7102 also has a bump 7110 extending from one corner. The bump 7110 makes the outermost leg of the hollow body 7102 more flexible so that it can be pulled away from other features of the wire organizer 7100 to increase the size of the slot 7106. The bump 7110 can also be used to separate one or more wires within the cavity 7104 for better organization. Although the hollow body 7102 is shown as having a generally square cross-section, other shapes can be used.

[0307] A tail 7112 extends from the hollow body 7102. The tail defines a surface 7114 that engages the base 206 of the solar panel frame 202. In certain embodiments, the surface 7114 can provide some support to the frame 202. The tail 7112 also has an upwardly extending portion 7115 that extends upwardly from the support surface 7114. The upwardly extending portion 7115 contacts and extends along the upwardly extending portion of the outer lip 108 and terminates in a fin 7116 having a retaining lip portion 7117 that, together with the upwardly extending portion 7115, defines a corner 7118. The corner 7118 engages the outer lip 208 of the solar panel frame 102. The engagement of both the corner 7118 and the retaining lip portion 7117 with the outer lip 108, as well as the engagement of the notch 7108 with the base extension 230, secure the wire dispenser 7100 about the solar panel frame 102. It is contemplated that the fin 7116, the retaining lip portion 7117, and the upwardly extending portion 7115 can be arranged in a variety of ways so long as the outer lip 208 can engage the corner 7118 as described herein. The fin 7116 can be used as a lever to lift the retaining lip portion 7117 and remove the outer lip 208 from the corner 7118, thereby enabling the wire dispenser to be removed from the panel frame 102. All elements of the wire dispenser 7100 can be made of a resilient or bendable material to allow the placement of wire into the cavity 7104 and to allow the wire dispenser 7100 to fit about the solar panel frame 202.

[0308] Reference is made to Figures 73-75 FIG. 30 shows a wire clip 7300. The wire clip 7300 includes a body 7301 that defines a U-shaped channel 7302 portion in which wire can be organized relative to the solar panel 202. The U-shaped channel portion 7302 defines a U-shaped cavity 7304 for storing wire between a contact wall 7306 arranged to contact and extend along a leg 210B, etc., of the solar panel frame 202 and an opposing wall 7307, 7308. Although the contact wall 7306 and the opposing wall 7307, 7308 are arranged to form the U-shaped cavity 7304, it is contemplated that the walls 7306, 7307 can take other shapes to retain wire in the cavity 7304.

[0309] A tail 7308 extends from the U-shaped channel portion 7302. The tail 7308 includes a top surface 7310 that, along with a portion of the contact wall 7306 opposite the bottom surface 7310, defines a notch 7312. The notch 7312 is arranged to fit the flange 230 of the solar panel frame 202 therein. The bottom surface 7310 extends away from the U-shaped channel portion 7302 at a downward angle such that it defines a space 7314 with the base 206 of the solar panel frame 202. This space 7314 can also be used to store and organize wire relative to the solar panel frame 202. An upward extending portion 7315 extends from the bottom surface 7310 and contacts an upward extending portion of the outer lip 208 of the solar panel frame 202. The upward extending portion 7315 terminates in a fin 7316 that includes a retaining lip portion 7317. The retaining lip portion 7317, along with the upward extending portion 7315, defines a corner 7318. The retaining lip portion 7317 and the corner 7318 engage the outer lip 1322 of the solar panel frame 202. The engagement of the corner 7318 with the outer lip 208 and the engagement of the notch 7312 with the base 206 secure the wire clip 7300 around the solar panel frame 202. It is contemplated that the fin 7316, the retaining lip portion 7317, and the upward extending portion 7315 can be arranged in a variety of ways so long as the outer lip 208 or cavity 212 can engage the retaining lip portion 7317 and the corner 7318 as described herein. The fin 7316 can be pressed downward, acting as a lever to withdraw the retaining lip portion from the outer lip portion and remove the outer lip portion 208 from the corner 7318, enabling the wire clip 7300 to be removed from the panel frame 202. All elements of the wire clip 7300 can be made of a resilient or bendable material to enable the wire to be placed into the U-shaped cavity 7304 and the wire clip 7300 to fit around the solar panel frame 102.

[0310] REFERENCE Figures 76-81A skirt assembly 7600 is shown. The skirt assembly 7600 includes a base 7602, a connecting piece 7604, and a skirt 7606. Generally, the base 7602 engages with an end of the solar panel frame 102, and the connecting piece 7604 is mounted to the base 7602 so that the skirt 7606 can be connected to both the base 7602 and the connecting piece 7604. A fastener 7608 connects the connecting piece 7604 to the base 7602. A spring (not shown) is placed around the fastener 7608 to push the fastener 7608 either upward or downward from within the base 7602. This action on the fastener 7608 pushes the connecting piece 7604 either upward or downward. If pushed upward, the connecting piece 7004 moves away from the base 7602, which will enable the module frame 102 to be more easily installed to the skirt assembly 7000. If pushed downward, the connecting piece is disposed more firmly against the base 7602, which requires the user to physically move the connecting piece 7604 before installing the module frame 102 to the assembly 7000.

[0311] The base 7602 includes a body 7610 that defines a hole 7612 for receiving the fastener 7608. The body 7610 is centrally located with respect to other features of the base 7602. Although the body 7610 is generally a cuboid or a cube, the body can take other shapes as long as the base 7602 can connect to the connecting piece 7604. A shelf 7614 extends from the body 7610 in a first direction. The shelf 7614 includes a surface that engages with the base 104 of the solar panel frame 102 and a lip 7615 to engage with the flange 230. The upwardly extending surface of the shelf 7614 and the body 7610 can be arranged to engage with the outer lip 108 of the solar panel frame 102. The upwardly extending surface of the body 7610 can directly contact the vertically extending portion of the outer lip 108. As shown in the figure, the body 7610 and the horizontal shelf 7614 define a corner that is complementary to the outer lip 108 and the base 106. A bent portion 7616 extends from the body 7610 in a direction opposite to that of the horizontal lip 7615. The bent portion 7616 includes a flat portion 7617 that extends in a direction opposite to that of the shelf 7614, and an angled portion 7619 that extends downward at an angle with respect to the flat portion 7617. The angled portion 7619 terminates in a hook 7618 that is used to engage with the skirt 7606, which will be described below.

[0312] The connection piece 7604 is generally assembled on top of the main body 7610 of the base 7602. The connection piece 7604 includes a main body 7620 that extends over the top surface of the main body 7610. The connection piece main body 7620 has an attachment lip 7621 that extends over one side of the main body 7610 so that the outer lip 108 of the solar panel frame 102 can be connected to the connection piece 7604. The main body 7620 defines an elongated hole 7622 to enable some horizontal movement of the connection piece 7604 as it is attached to the base main body 7610. A downward leg 7624 extends downward from the main body 7620 adjacent to one side of the main body 7610 opposite the side adjacent to the attachment lip 7621, which helps to secure and / or align the connection piece 7604 to the main body 7610. An upward leg 7626 extends upward from the main body 7620 and opposite the downward leg 7624. The upward leg has a rounded end 7628 that terminates in a tab 7630. The tab 7630, the rounded end 7628, and a portion of the upward leg 7626 define a hook 7632 that is configured to engage with a portion of the apron 7606, which will now be described.

[0313] The skirt 7606 includes an elongated body 7634 that extends at an angle along the entire length of the skirt 7606. The elongated body 7634 is shaped such that when the skirt 7606 is fully installed, the elongated body 7634 can provide a covering for wires, other electronic features, mounting accessories, and other structures used with a solar panel system. The elongated body 7634 can also provide a smooth, clean, and visually appealing appearance at the edges of a solar panel array. An upper flange 7636 extends from the top end of the elongated body 7634. The upper flange 7636 reduces the exposure of the base 7602 when the skirt 7606 is applied to the base 7602 and includes a hooked end that can be used to install the skirt 7606 to certain features of a solar panel system. These features are not shown herein, but a person of ordinary skill in the art can understand the method of use of these features from the description of other similar features discussed in connection with the skirt assembly 7600. A first intermediate flange 7638 extends from the elongated body 7634 a distance below the upper flange 7636. The first intermediate flange 7638 extends at an angle relative to the elongated body 7634 and terminates in a hook 7640. The hook 7640 is curved to fit within the hook 7632 defined between the tab 7630, the circular end 7628, and the upwardly directed leg 7626 of the connecting piece 7604. As shown in the figures, the hook 7640 extends straight upward relative to the other features of the skirt assembly 7600, as shown in the figures. A person of ordinary skill in the art will recognize the relative orientation of the hook 7640 relative to the other features described herein based on the pitch of the roof that can be applying these features. However, the hook 7640 can extend in other directions given the slope and arrangement of the hook 7632 and other features relative to a pitched roof or other mounting surface. A second intermediate flange 7642 extends from the elongated body a distance below the first intermediate flange 7638. The second intermediate flange terminates in a hook 7644. The hook 7644 engages with the hook 7618 at the end of the bent portion 7616 of the base 7602. As shown in the figures, the hook 7640 extends generally parallel to the elongated body 7634. However, the hook 7640 can extend in other directions given the slope and arrangement of the hook 7618. The elongated body 7634 terminates in an end hook 7646.

[0314] Assembly of the skirt assembly 7600 will now be described. First, the connecting piece 7604 is placed on the base 7602 with the hole 7622 aligned with the hole 7612 so that the fastener 7608 can be inserted to connect the connecting piece 7604 to the base 7602. The counterbore on the hole 7622 and the elongated nature of the hole 7622 allow for some lateral movement of the connecting piece 7604 along the top of the body 7610. Assembly of the fastener 7608, spring (not shown), connecting piece 7604, and base 7602 can be performed during manufacture of the skirt assembly 7600 or at any point prior to delivery. The fastener head can extend a distance above the connecting piece 7604. The pre-set height and the elongated nature of the hole 7622 allow the mounting lip 7621 to be tilted upward relative to the body 7610 and over the outer lip 108 of the frame 102. This is accomplished by pulling the tab 7630 back and down, which acts as a lever for the connecting piece 7604. This leverage is aided by a spring that extends around the fastener 7608. The spring is between the head of the fastener 7608 and the connecting piece 7604 and pushes the connecting piece toward the base 7602. This pushing of the connecting piece 7604 by the spring toward the base 7602 allows the assembly 7600 to be placed on the frame 102 and held in place without the need to tighten the fastener 7608. The attachment lip 7621 can then be aligned relative to the outer lip 108, and / or the clamp cavity 112 of the solar panel frame 102. The tab 7630 is then pulled back and released so that the outer lip 108 can engage with the attachment lip 7621. For this arrangement, the skirt 7606 can be installed by snapping the hooks 7640, 7644 of the skirt 7606 into place in the hooks 7632 and 7618.

[0315] First, hook 7644 is inserted into hook 7618 to engage second intermediate flange 7642 with assembly 7600, and then the skirt is rotated to move top flange 7636 toward assembly 7600 and frame 102. This engages first intermediate flange 7628 with assembly 7600. As hook 7640 approaches assembly 7600, hook 7640 engages the angled bottom surface of tab 7630, which pushes connecting piece 7604 upward until the rounded end 7628 extends past hook 7640 and the connecting piece 7604 snaps down, thereby capturing hook 7640 within hook 7632. Then fasteners 7608 are tightened, and skirt 7606 and assembly 7600 are secured to frame 102. All of the elements of skirt assembly 7600 can be made of a resilient and bendable material to help achieve the different connections described herein. When skirt 7606 is in place, upper flange 7636 covers a portion of base 7602 and connecting piece 7604 so that only fasteners 7608 are exposed, which enables an installer to access fasteners 7608. The upper flange 7636 extending over base 7602 and connecting piece 7604 protects these elements and some features below these elements from adverse weather or snow.

[0316] While frames 102 and 202 are discussed primarily in connection with the mounting clamps discussed in this section, it should be understood that other module frames disclosed herein can be used with the foregoing features without much or any modification to the clamps or frames.

[0317] Support structures and other mounting clamps

[0318] Figures 82A-110 Support structures 8200 are shown individually and connected to various module clamps, some of which have been discussed previously. Support structure 200 and its associated features are used to mount a solar panel to a support surface. The support surface can be a roof or other structure on which a solar panel can be disposed. Typically, multiple support structures 8200 are used to support a single solar panel, while a single support structure 8200 is disposed to support part of two solar panels disposed within a larger array. Support structure 8200 can also be used to mount a single solar panel in situations where only one panel is used.

[0319] Reference Figures 82A-89 Support structure 8200 has a base 8212 and a pedestal 8214, as well as a mounting fastener 8216 disposed to support a mounting component, which are discussed below. Pedestal 8214 is mounted relative to base 8212 and is movable relative to base 8212, and mounting fastener 8216 is mounted relative to pedestal 8214. In Figure 82AIn the embodiment shown in FIG. 82, the mounting fastener 8216 is received within the mounting hole 8236, but the fastener 7616 is not movable within the hole 8236. In this embodiment, a nut or bolt head is on such an end of the mounting fastener 8216 that engages an end of the mounting hole 8236 or other portion of the base 14 to prevent movement. Figure 82B In the embodiment shown in FIG. 82, the mounting fastener 8216 is received within the mounting hole 8236, but the fastener 7616 is not movable within the hole 8236. In this embodiment, a nut or bolt head is on such an end of the mounting fastener 8216 that engages an end of the mounting hole 8236 or other portion of the base 14 to prevent movement.

[0320] The base 8212 defines a slot 8222 in or on which the base 8214 moves. The base 8214 can slide along and within the slot 8222 in the direction indicated by arrow P in FIGS. 82 and 83. Extensions 8846A, 8846B extend from the base 8214 into the slot 8222 to properly align the base 8214 within the slot 8222. A groove 8228 is defined within the slot 8222, and the groove 8228 can receive the extensions 8846 to secure the base 8214 to the slot 8222. As shown in the figures, the extensions 8846 extend from a space around the base hole 8238. However, the extensions 8846 can extend from any area along the bottom of the base 8214, and any number of extensions can be used. In some cases, the extensions 8846 can extend from a side of the base 8214 and engage a sidewall of the slot 8222. Figure 82A and 82B The base 8212 defines a slot 8222 in or on which the base 8214 moves. The base 8214 can slide along and within the slot 8222 in the direction indicated by arrow P in FIGS. 82 and 83. Extensions 8846A, 8846B extend from the base 8214 into the slot 8222 to properly align the base 8214 within the slot 8222. A groove 8228 is defined within the slot 8222, and the groove 8228 can receive the extensions 8846 to secure the base 8214 to the slot 8222. As shown in the figures, the extensions 8846 extend from a space around the base hole 8238. However, the extensions 8846 can extend from any area along the bottom of the base 8214, and any number of extensions can be used. In some cases, the extensions 8846 can extend from a side of the base 8214 and engage a sidewall of the slot 8222.

[0321] Base fasteners 8224 and slide nut 8234 secure base 8214 at a desired position along slot 8222. Base fasteners 8224 are shown as screws, but can be other fasteners known in the art. Base 8214 defines base holes 8238 to receive base fasteners 8224. Base holes 8238 can be considered second holes. Base fasteners 8224 can have threads corresponding to threads on base holes 8238 to secure base fasteners 8224 to base 8214. Slide nut 8234 is also disposed within slot 8222 to receive base fasteners 8224 so that fasteners 8224 can secure base 8214 in a desired position. Slide nut 8234 can also have threads corresponding to threads on base fasteners 8224 and in base holes 8238 to facilitate connection. By tightening base fasteners 8224 within base holes 8238 and slide nut 8234, base 8214 is secured in place at a desired position by a friction fit and cannot slide or otherwise move along or within slot 8222. Loosening base fasteners 8224 reduces the force applied to base 8214, which enables base 8214 and slide nut 8234 to slide within slot 8222. This enables base 8214 to be secured at different positions along slot 8222 to facilitate installation. Slot 8222 defines a channel 7628 2828 that can receive or otherwise engage slide nut 8234 to keep slide nut 8234 secured within slot 8222 and slidable within the slot.

[0322] The fasteners 8216, 8224 and the holes 8236, 8238 can be arranged at different angles relative to the slot 8222 and the base 8212 to facilitate mounting of the base 8214 to the base 8212. As shown in the figures, the mounting hole 8236 is arranged orthogonal to the slot 8222 and the base hole 8238 is arranged to define an acute angle with the mounting hole 8236. This also forms an obtuse and acute angle with the slot 8222. The orthogonal angle defined between the mounting hole 8236 and the slot 8222 enables the mounting fastener 8216 to be raised and lowered in a generally vertical manner relative to the base 8212, which enables the height of the solar panel module to be adjusted after the support structure is mounted substantially perpendicular to the roof plane. In embodiments where the mounting fastener 8216 is fixed, the orthogonal arrangement still enables a nut or other feature for supporting a support mounting component on the mounting fastener 8216 to be raised or lowered to adjust the height of the mounting component in a direction perpendicular to the roof plane. The base 8214 includes a cylindrical body 8248 that contains the mounting hole 8236 and an extension body 6650 that extends from the cylindrical body 8248 that contains the base hole 8238. The extension body 6650 generally takes the shape of a right triangle when viewed in the direction of extension from the cylindrical body 8248. However, the extension body 6650 can take other shapes that enable the base 8214 to engage with the slot 8222.

[0323] The base 8212 is secured to a support surface by a plurality of base fasteners 8226. As shown in the figures, the base fasteners 8226 are screws, but other fasteners known in the art can be used. The base fasteners 8226 are received within base holes 8240. The base holes 8240 can be considered third holes. The base holes 8240 extend through the base 8212 and enable the base fasteners 8226 to secure the base 8212 to a support surface on which the base is mounted. The base holes 8240 are generally arranged near the end of the slot 8222. In particular, the base 8212 defines a foot 8242 and a toe 8244. The foot 8242 includes the base holes 8240 and the toe 8244 extends from the foot 8242. The slot 8222 extends from the foot 8242 along the toe 8244. As shown in the figures, there are three base holes 8240 8240A that surround the end of the slot 8222 on the foot 8242 of the base 8212. These base holes 8240 8240A are arranged to extend into the base 8212 at a non-orthogonal angle. The base holes 8240 8240A can also define an acute angle with the direction of the mounting hole 8236 and the mounting fastener 8216.

[0324] As shown in the figures, there are two base holes 8240B arranged proximate the outer edge of the base 8212 relative to the base holes 8240A. These base holes 8240B are further from the slot 8222 relative to the base holes 8240A. In other words, one or more of the base holes 8240A can be disposed between the slot 8222 and the base holes 8240B. The base holes 8240B extend straight into the base 8212 so as to define a right angle with the bottom surface area of the base 8212. The base holes 8240B also extend parallel to the mounting holes 824836. The different angles of the base holes 8240A, 8240B enable a more secure connection between the base 8212 and the support surface. As shown in the figures, there are five base holes 8240, three of which 8240A extend at a non-right angle relative to the base 8212, and two of which 8240B extend at a right angle relative to the base 8212. It should be understood that the base holes 8240 can be arranged in a variety of ways around the base 8212, with each base hole 8240 extending into the base 8212 at a different or the same angle relative to the base 8212, the bottom surface area defined by the base 8212, or other features discussed herein.

[0325] Depending on the manner in which the support structure 8200 is installed and the time of installation, it can be desirable to first engage the base fasteners 8226 with one of the base holes 8240A, 8240B and then the other. In some cases, the base fasteners 8226 are first secured to all of the base holes 8240A and then to the base holes 8240B. By connecting the base 8212 to the support surface in this manner, the forces generated by the connection of the fasteners 8226 act on the base 8212 in a direction perpendicular to the support surface and parallel to the support surface (defined by the angle of the holes 8240A). These forces push the base 8212 and the support structure 8200 in the direction defined by the holes 8240A. The forces exerted in the parallel direction act on the mounting components connected to the support structure 8200 and push the mounting components against the solar panel modules to which they are mounted. This provides additional force to secure the solar panel modules in place against their respective mounting components and the support structure 7600. After the fasteners 8226 have been secured to the holes 8240A, the fasteners 8226 are then secured to the holes 8240B. The application of the fasteners 8226 to the holes 8240B provides additional force to secure the base 8212 to the support surface.

[0326] In other cases, the base fastener 8226 is fastened to the base hole 8240B before being fastened to the hole 8240A. By connecting the base 8212 to the support surface in this manner, the force applied by the fastener 8226 to the base hole 8240B acts in a direction perpendicular to the support surface, thereby directly securing the base 8212 against the support surface. This ensures that the base 8212 and support structure 8200 are secured vertically to the support surface before the fastener 8226 is applied to the hole 8240A, which minimizes the horizontal push on the base 8212 due to the engagement between the fastener 8226 and the hole 8240A. The application of the base fastener 8226 to the base holes 8240A, 8240B and the order in which they are applied will be discussed in more detail below.

[0327] A pad 8230 is provided on the underside of the base 8212 to prevent water from leaking into or along the support surface due to the base fastener 8226 drilling into the support surface. The pad 8230 can be made of a material that creates a seal between the base 8212 and the support surface, which prevents water from traveling through the hole that the fastener 8226 extends through. In addition to forming a seal, the pad 8230 can also create a barrier that makes it difficult for water to enter the hole created by the fastener 8226. In some cases, the pad 8230 can not form a perfect seal, but it can still sufficiently prevent water from seeping into the support surface so that it does not damage the support surface or items located outside of the support surface. When the support surface is a wooden shingle roof, the pad 8230 can be shaped and sized to fit a single shingle or layer of shingles.

[0328] Figures 90-111 Different mounting components are shown, and their use with a support structure will now be described. In a first example, reference is made to Figures 90-93 , showing Figures 34-39 a lever clamp 3400 attached to the support structure 8200 shown in Figure 82A . This support structure 8200 includes a head 8217 on a mounting fastener 8216 that enables the fastener 7616 to be raised or lowered relative to the base 8214. To secure the lever clamp 3400 to the mounting fastener 8216, a nut 8218 is secured to the mounting fastener 8216 and the holes 3416, 3418 are aligned with the mounting fastener 8216 so that the mounting fastener 8216 is received within the holes 3416, 3418. The nut 8218 supports the lever clamp 3400 on the mounting fastener 8216. Although a nut 8218 is shown, other securing mechanisms can be used, such as a rod, washer, or other threaded bolt that extends through the mounting fastener 8216.

[0329] As Figure 92As shown, the mounting fastener 8216 includes a head portion 8217, a threaded portion 8221, and a straight shaft portion 8219 located between the two. The straight shaft portion 8219 has a larger outer diameter than the threaded portion 8221. A nut 8218 is tightened against the bottom of the straight shaft 8219. The mounting fastener head 6617 is located above the top surface of the upper connector 8214, the nut 8218 is located below the bottom surface of the base 3402, and the straight shaft 8219 is received by holes 8216, 8218, which are unthreaded clearance holes. The length of the straight shaft is greater than the height of the clamp base 8202 from the bottom surface of the clamp base 8202 to the top surface of the upper connector 2214. This allows the mounting fastener 8216 to rotate freely within the clamp 3400 and allows a drill bit or other tool to move the mounting fastener 8216 up and down within the mounting hole 8236. With the lever fastener 3400 in the engaged position, the solar panel module can be rocked into the appropriate position between the second mounting lip 3432 and the second support flange 3418. Further installation of the support structure 8200 and the lever clamp 3400 will be discussed below.

[0330] In the second example, refer to Figures 94-97 , showing Figures 48-52 Attached to Figure 82A The support structure 8200 shown includes a mounting clamp 4800. The support structure 8200 also includes a head 8217 on the mounting fastener 8216, which allows the fastener 7616 to be raised or lowered relative to the base 8214. To secure the mounting clamp 4800 to the mounting fastener 8216, two nuts 7618A and 7618B are tightened against each other, locking them in place and securing them to the mounting fastener 8216. The mounting hole 4828 is aligned with the mounting fastener 8216 so that the fastener 8216 is received within the mounting hole 4828. The mounting fastener head 8217 is located above the top surface of the base 4802, the locking nuts 8218A and 8218B are located below the bottom surface of the base 4802, and the fastener 6616 is received within the mounting hole 4828, which is a non-threaded clearance hole. The distance between the bottom of head 8217 and the top of locking nuts 8218A, 8218B is greater than the height of the clamp base 8202 from the bottom surface to the top surface of the base 8202. This allows the mounting fastener 8216 to rotate freely within the clamp 4800 and allows a drill bit or other tool to move the mounting fastener 8216 up and down within the mounting hole 8236 without rotating the clamp 4800. Once the base 4802 is secured, the solar panel module can be rocked into the appropriate position within either of the mounting spaces 4816, 4818.

[0331] In a third example, reference is made to Figures 98-102 , showing another mounting clamp 9800 attached to the support structure 8200 shown in Figure 82A . The clamp 9800 includes a base 9802 and a top portion 9804 connected to or at least partially received within the base 9802. The base 9802 includes support flanges 9806, 9808 extending from opposite sides to support a solar panel frame mounted to the clamp 9800. A central portion 9810 extends between the support flanges 9206, 9208. Side walls 9807, 9809 extend upwardly from the base 9802 in the area between one of the support flanges 9806, 9808 and the central portion 9810. The top portion 9804 is disposed above the base 9802 and includes a first clamping flange 9812 extending in one direction and opposite the first support flange 9806. The top portion 9804 also includes a second clamping flange 9814 extending opposite the first clamping flange 9812. The second clamping flange 9814 is opposite the second support flange 9808.

[0332] The clamping flanges 9812, 9814 can include features to connect or bond to a solar panel frame to be engaged with the clamp 9800. The first support flange 9806 and the first clamping flange 9812 define a first mounting space 9816 therebetween, and the second support flange 9808 and the second clamping flange 9814 define a second mounting space 9818 therebetween. The mounting spaces 9816, 9818 are arranged to receive a solar panel frame therebetween and secure the solar panel frame to the clamp 9800 for mounting in an array or other solar panel system. The top portion also includes side walls 9820, 9822 extending from the clamping flanges 9812, 9814 toward the base 9802. Connection portions 9824, 9826 extend between the side walls 9820, 9822.

[0333] The base 9802 defines a connection hole 9830, and the connection portion 9822 defines a connection hole 9832 aligned with the connection hole 9830. These holes 9830, 9832 are aligned to receive a connection fastener 9834 therethrough. The connection fastener 9834 connects the top portion 9804 to the clamp base 9802. The connection holes 9830, 9832 and the connection fastener 9834 can have corresponding threads to facilitate such connection. In some embodiments, only the connection hole 9830 and the connection fastener 9834 can have corresponding threads. The connection fastener 9834 can be adjusted to move the top portion 9804 relative to the base 9802, which will change the relative arrangement of the features of both the base 9802 and the top portion 9804.

[0334] In the embodiment of support clamp 9800, mounting fastener 8216 is fixed within base 8214 and cannot rotate or move up and down. As shown in FIG. 79, Figure 101 Base 8214 includes a hexagonal recess 8239 extending upwardly from the bottom surface of base 8214. This recess 8239 receives the hexagonal head of fastener 8216 and prevents fastener 8216 from rotating within base 8214. The recess 8239 and the head 8217 are hexagonal in shape, but can take other shapes, such as square or any other shape, as long as the recess and head have a matching shape that prevents movement of fastener 8216 within base 8214. Other methods for limiting such movement can also be considered, such as pinning fastener 8216 to the base, or providing matching threads on hole 8236.

[0335] Base 9802 also defines a mounting hole 9836, and top portion 9804 defines a mounting hole 9838 that is aligned with mounting hole 9836. Mounting holes 9836, 9838 are clearance holes and are arranged to receive mounting fastener 8216 so that clamp 9800 can be connected to support structure 8200. A flanged elongated hex nut 9821 is provided over mounting fastener 8216 and is arranged so that the flange is below base 9802 of clamp 9800 and supports the base. When mounting fastener 8216 is received within mounting holes 9836, 9838, hex nut 9821 supports base 9802 over mounting fastener 8216. Hex nut 9821 includes a flange 9823 that extends radially beyond a hex portion 9825. Mounting hole 9836 is sized as a clearance hole for the hex portion 9825 of hex nut 9821, which allows the nut to turn and rotate within hole 9836. Flange 9823 is larger than hole 9836, and thus supports clamp base 9802 from below. Hex nut 9821 and mounting fastener 8216 can have corresponding threads so that hex nut 9823 can engage and rotate clockwise and counterclockwise with fastener 8216. This allows flange 9823 to be adjusted up and down along fastener 8216, thereby adjusting the height of clamp base over base 8212 and the support surface or roof, and in turn adjusting the position of clamp 9800 while maintaining the orientation of clamp 9800.

[0336] The top portion 9804 further defines access holes 9840, 9842 that are located above and aligned with the connection holes 9830, 9832 and the mounting holes 9836, 9838. The access holes 9840, 9842 are provided to enable a user to access the mounting fasteners 8216 and the connection fasteners 9834 to adjust these features as needed. In some embodiments, the fasteners 8216, 9812 can be adjusted with a drill bit (not shown) having one or more interchangeable heads that can mate with the ends of the mounting fasteners 8216 and the connection fasteners 9812 to cause these parts to rotate within the clamp 9800.

[0337] In a fourth example, referring to Figures 103-106 , a mounting component 10300 is shown. The mounting component 10300 is a one-piece part having a bottom portion 10302, center walls 10303, 10305 extending from the bottom portion 10302, and a top portion 10304 extending from the center walls 10303, 10305. The bottom portion includes support flanges 10306, 10308 extending in opposite directions to support a solar panel frame thereon. A center portion 10310 extends between and connects the support flanges 10306, 10308. The top portion 10304 includes a first clamping flange 10312 extending in one direction and opposite the first support flange 10306. The top portion 8204 also includes a second clamping flange 10314 extending opposite the first clamping flange 10312. The second clamping flange 10314 is opposite the second support flange 10308. A center portion 8713 extends between and connects the clamping flanges 10312, 10314.

[0338] The clamping flanges 10312, 10314 can include features to connect or bond to a solar panel frame to be engaged with the clamp 10300. The first support flange 10306 and the first clamping flange 10312 define a first mounting space 10316 therebetween, and the second support flange 10308 and the second clamping flange 10314 define a second mounting space 10318 therebetween. The mounting spaces 10316, 10318 are arranged to receive a solar panel frame therebetween and secure the solar panel frame to the clamp 9800 for mounting in an array or other solar panel system.

[0339] The center portion 10310 defines a mounting hole 10320, and the center portion 8713 defines a mounting hole 10322. The mounting holes 10320, 10322 are aligned and arranged to receive a mounting fastener 8216 therein. To arrange the mounting component 10300 on the mounting fastener 8216, a barrel nut 10324 is connected to the mounting fastener 8216 and extends along its length. A barrel portion 10326 of the barrel nut 10324 is threaded to connect to the mounting fastener 8216, and an extension 10328 extends over the mounting fastener 8216 in a direction away from the base 8212. The mounting holes 10320, 10322 are clearance holes so that the extension 10328 fits within at least the first mounting hole 10320, and the bottom portion 10308 rests on the barrel portion 10326 for support.

[0340] In the embodiment of the support clamp 10300, the mounting fastener 8216 is fixed within the base 8214 and cannot rotate or move up and down. As shown in Figure 89 The base 8214 includes a hexagonal recess 8239 extending upwardly from a bottom surface of the base 8214. This recess 8239 receives the hexagonal head 8217 of the fastener 8216 and prevents the fastener 8216 from rotating within the base 8214. The recess 8239 and the head 8217 are hexagonal in shape, but can take other shapes such as square or any other shape, as long as the recess and the head have a matching shape that prevents movement of the fastener 8216 within the base 8214. Other methods for limiting such movement can also be considered, such as pinning the fastener 8216 to the base, or providing matching threads on the hole 8236, or using chemical epoxy.

[0341] In a fifth example, reference is made to Figures 107-111 Another mounting component 10700 is shown. This mounting component 10700 includes a base 10702 and a top portion 10704 arranged above the base 10702. As shown in the figure, the top portion 10704 is arranged above only a portion of the base 10702. The base 10702 includes support flanges 10706, 10708 extending from opposite sides to support a solar panel frame mounted to the clamp 10700. A center portion 10710 extends between the support flanges 10706, 10708. Sidewalls 10707, 10709 extend upwardly from the center portion 10710, and a shelf 10711 extends between and connects the sidewalls 10707. The sidewalls 10707, 10709 and the shelf 10711 define a space 10713, and each of these elements extends along the entire width W of the base 10702. The top portion 10704 is supported by the shelf 10711 along a portion of the width W.

[0342] The top portion 10704 includes a first clamping flange 10712 that extends in one direction and is opposite the first support flange 10706. The top portion 10704 also includes a second clamping flange 10714 that extends opposite the first clamping flange 10712. The second clamping flange 10714 is opposite the second support flange 10708. The clamping flanges 10712, 10714 can include features to connect or bond to a solar panel frame to be engaged with the clamp 10700. The first support flange 10706 and the first clamping flange 10712 define a first mounting space 10716 therebetween, and the second support flange 10708 and the second clamping flange 10714 define a second mounting space 10718 therebetween. The mounting spaces 10716, 10718 are arranged to receive a solar panel frame therebetween and secure the solar panel frame to the clamp 10700 for installation in an array or other solar panel system. The top portion 10704 also includes side walls 10720, 34103410722 that extend from the clamping flanges 10712, 10714 in a direction toward the base 10702. The side wall 10720 begins proximate the first clamping flange 10712 and extends a distance such that it terminates at or proximate the support flange 10706, covering the side wall 10707. The side wall 34103410722 extends a distance such that it terminates at or proximate the shelf 10711, exposing the side wall 10709. It is contemplated that other lengths can be used. Connection pieces 10724, 10726 extend between the side walls 10720, 34103410722 to connect them, with the connection piece 10724 disposed on the shelf 10711 and the connection piece 10726 extending between the side walls 10720, 34103410722 proximate the clamping flanges 10712, 10714.

[0343] The shelf 10711 defines a first connection hole 10730, the first connection piece 10724 defines a second connection hole 10732, and the second connection piece 10726 defines a third connection hole 10734. Each of these connection holes 10730, 10732, 10734 are aligned to receive a connection fastener 4810736 therethrough. The connection fastener 10736 includes a threaded portion 10738 that mates with corresponding threads in the connection hole 10730. The connection holes 10732, 10734 can also have corresponding threads, or they can be clearance holes for the connection hole 10730. This arrangement secures the top portion 10704 to the base 10702.

[0344] The center portion 10710 defines a first mounting hole 10740, and the shelf 10711 defines a second mounting hole 10742. The mounting holes 10740, 10742 are arranged to receive a mounting fastener 8216 therethrough. One or both of the mounting holes 10740, 10742 can be a clearance hole. To facilitate such connection, a sleeve 10744 is provided to extend over the mounting fastener 8216. The sleeve 10744 includes an upper sleeve portion 10750, a lower sleeve portion 10748, and an integral nut portion 10746 therebetween. The sleeve nut 10746 of the sleeve 10720 is threaded so that the sleeve 10720 can be secured to the mounting fastener 8216. The diameter of the sleeve nut 10746 is greater than the mounting hole 10740, thereby ensuring that the base 10702 will seat against the nut portion 10746 when mounted. The lower sleeve portion 10748 is arranged to be outside of the base 10702, and to extend in a direction toward the base 8212. The upper sleeve portion 10750 of the sleeve 10744 is arranged to be inside of the base 10702, and to extend through at least the first mounting hole 10740 and terminate outside of or proximate to the second mounting hole 10742. The length of the upper sleeve portion 10750 is greater than the height of the base 10702, measured from the bottom surface of the center portion 10710 to the top surface of the shelf 10711. The top end of the upper sleeve portion defines a threaded hole configured to receive a drive fastener 10743. The drive fastener 10743 includes a threaded portion received by the threaded hole in the top end of the upper sleeve portion 10750, and a flanged drive head 8217. The diameter of the flange of the drive head is greater than the diameter of the hole 10742. The drive fastener 10743 is secured to the upper sleeve portion by being firmly tightened into the upper sleeve portion 10750 and / or using Loctite or similar adhesive.

[0345] The sleeve nut 10722 can be at the midpoint of the sleeve 10744, and separates the lower sleeve 10748 from the upper sleeve 10750. An exemplary method of installing and adjusting one or more support structures 9810 will now be described. Although the installation of a solar panel module in connection with the mounting component is discussed, the skilled artisan will understand how similar methods can be used with the mounting component. Typically, a plurality of support structures 10 are connected to a single solar panel module to secure the module to a support surface. In one example, four support structures 9810 are used, with two on each of opposite sides of the module. In another example, six support structures 9810 are used, with three on each of opposite sides of the module. The installation method is substantially the same for each example.

[0346] In embodiments of support clamp 10700, mounting fastener 8216 is fixed within base 8214 and cannot rotate or move up and down. As shown in FIG. 107, Figure 95 Base 8214 includes a hexagonal recess 8239 extending upwardly from the bottom surface of base 8214. This hexagonal recess receives the hexagonal head 8217 of fastener 8216 and prevents fastener 8216 from rotating within base 8214. The shapes of recess 8239 and head 8217 are hexagonal, but can be other shapes such as square or any other shape, as long as the recess and head have matching shapes that prevent movement of fastener 8216 within base 8214. Other methods for limiting such movement can also be considered, such as pinning fastener 8216 to the base, or providing matching threads on hole 8236, or using chemical epoxy.

[0347] Sleeve 10744 includes internal threads that mate with the threads of mounting fastener 8216. Flanged drive head 8217 is above the top surface of shelf 9111, nut portion is below the bottom surface of central portion 10710 and supports the bottom surface of the central portion, upper sleeve portion is within base 10702, and mounting fastener 8216 threadably interacts with sleeve 9144. Drive head 8217 can be rotated using a drill bit or other tool, upper sleeve portion 9150 is free to rotate within base 10702, and sleeve 10744 is driven up and down on mounting fastener 8216, thereby adjusting the height of clamp 10700 above base 8212 and the mounting surface.

[0348] Prior to installation, the support structure 8200 has been connected to the mounting components. The clamps 3400, 4800, 9800, 10300, 10700 are connected to the module frame in order to mount the support structure to both sides of the module, preparing the first row of solar modules for installation. The prepared module is then placed on the mounting surface and the support structure 8200 is arranged at the desired location on the support surface, which can be close to the pitch of the roof or generally at the lower position of the pitch of the roof. If the support surface is a shingled roof, the pads 8230 can be aligned within a single layer of shingles. Any backing on the pads 8230 will be stripped away so that the pads 8230 directly contact the support surface. The base fasteners 8226 are tightened into their respective base holes 8240A, 8240B, securing the support structure 8210 to the support surface. First, the base fasteners 8226 corresponding to the orthogonal base holes 8240B are installed, ensuring that the base 8212 of the support structure 8210 is connected to the support surface. Then, the base fasteners 8226 corresponding to the angled base holes 40A are installed. At this point, installation accessories such as aprons or wind screens can be connected to the mounting components on one side. This side can be the downhill side of the clamping components corresponding to the toe 8244 of the base 8212. The first row can then be straightened and leveled by tightening the cord, then adjusting the base 8214 along the slot 8222 and then adjusting the height of the clamp base 3402, 9802, 10302, 10702, to all align with the cord that is tensioned between the outside end components.

[0349] Next, the first row of modules can be installed into the first row support structure 8210 by placing one side of the module on the uphill support flange, tucking the top edge of the module frame under the clamp flange; or placing the installation lip on the module frame under the installation lever 205, then rotating the uphill side of the module toward the roof.

[0350] When the module frame approaches the roof, additional support structures are installed to the upper slope frame of the module by installing the module frame into the component space. If needed, the base 8212 can now be adjusted along the base by loosening the base fasteners 8224 and sliding the base 8212 so that the entire flashing pad falls into a single course of shingles, and re-tightening the base fasteners 8224. The release liner can be removed from the flashing pad, and the support structure can be placed directly on the support surface. Next, the base fasteners 8226 corresponding to the angled base holes 8240 8240A are installed and tightened into the roof / support surface. This causes the support structure and clamping component to be tightly against the module frame. Then, the base fasteners 8226 corresponding to the orthogonal base holes 8240 8240B are installed and tightened into the roof / support surface, thereby securing the support structure and module to the roof / support surface. This process is performed along the first row of modules, and then along all subsequent rows of modules until all modules are installed and secured to the roof / support surface.

[0351] Additional support structures 8200 and mounting components are connected to the upper slope side of the solar panel module by clamping the module frame within the mounting space. The opposite second side of the module has not yet been connected to the mounting components 8200. This second side is pushed or rotated into place so that it engages with the support structure and mounting components 8200 that have been installed to the support structure. In other words, the frame on the second side of the solar panel module is shaken into place within the mounting space of the mounting components 8200 that have been secured to the support surface. The first side of the solar panel module is then rotated down until the base 8212 of the support structure 8210 can be disposed on the support surface. The base 8212 can be moved relative to the base 8214 before the support structure 8200 is installed to the support surface to enable the base 8212 to be secured so that the pad 8230 is on a single tile if needed. Any backing on the pad 8230 should be removed before the pad 8230 is placed against the support surface. When the base 8212 is aligned with the desired location, the base 8214 is secured relative to the base 8212 by tightening the base fasteners 8224. When the base 8212 and pad 8230 are placed on the support structure, the base fasteners 8226 corresponding to the angled base holes 8240 8240A are installed first to firmly push the base 8212 in the direction of the solar panel module. Then, the base fasteners 8226 corresponding to the orthogonal holes 8240B are installed. If needed, the height of the mounting component 8200 can be adjusted at this time by moving the mounting fasteners 8216. Because each mounting component 7600 allows two solar panel modules to be installed on opposite sides, the process can be repeated for new solar panel modules until the desired number of solar panel modules are installed within the array.

[0352] In another example, a first solar panel module can be connected to the mounting component 8200 with the module frame engaged within the mounting space along two opposite sides of the solar panel module. The solar panel module and connected support structure 8200 are then placed on the support surface at the desired location, and the base 8212 of the support structure 8210 is arranged so that the base fasteners 8226 can be threaded into their respective base holes 8240A, 8240B. If the support structure is a shingled roof, the pads 8230 can be arranged on a single shingle layer. The base 8214 can be slid along the slot 8222 to ensure that the pads 8230 are seated on the single shingle before the base fasteners 8226 are applied to the base 8212. After the base 8212 is secured by the base fasteners 8226, the base 8214 is secured by threading the base fasteners 8224 into the base holes 8238. This secures the first solar panel module in place on the support surface. If only one solar panel is used, the installation can stop here. To arrange a second solar panel module in the array after the first module has been installed, the mounting component 100 is engaged along the first side with the second solar panel module, and the opposite second side is engaged with the already secured mounting component 8200 in the same manner as described above. These steps can be repeated until the entire solar panel array is formed from the installed modules.

[0353] In another example, only one side of the first solar panel module can engage with the mounting component 8200. This means that initially only one half of the frame of the solar panel module is secured within the mounting space. The support structure 8200, connected to the solar panel module, is then positioned at the desired location on the support surface, and base fasteners 8226 are installed in their respective base holes 8240A, 8240B to secure the base 8212 of the support structure 8210 to the support surface. If the support structure is mounted on a shingle roof, the base 8212 can be arranged such that a pad 8230 is placed on a single shingle layer. After these support structures 8210 are installed on the support surface, an additional support structure 8200 with mounting components is arranged on the other half of the solar panel module. The base 8214 and mounting fasteners 8216 are adjusted as needed so that the base 8212 rests flat on the support surface and the solar panel module frame is received within the mounting space. Next, thread the base fastener 8226 into the base holes 8240A and 8240B. To install the second solar panel module, assemble one side of the solar panel module into the open mounting space of the already installed mounting components. Then, tilt or otherwise position the second module at the desired height so that the additional mounting components 8200 and support structures can be arranged to support the other half of the second module in the same manner as just described. This process can be repeated until the desired number of solar panel modules are installed.

[0354] The adjustability of the mounting components allows for the removal and replacement of individual solar panel modules within the array. This also allows for the use of solar panel modules of varying thicknesses within the array. The adjustability of the base 8214 and mounting fasteners 8216 further facilitates the easy removal and replacement of individual solar panel modules and the use of modules of different sizes within the array.

[0355] Additional module framework

[0356] refer to Figures 114-116 This illustrates another embodiment of a solar panel frame 11402. This frame 11402 includes the same features as the other frames 102, 202, 302, 402 described herein, and is mounted to other clamps and accessories in a similar manner, wherein a clamp cavity 11412 is defined between an outer lip 11408 and a first leg 11410A. Although not described in this section, Figures 114-116 The features shown are Figures 1-4Features shown with the same last numeral in the figures are similar or identical. The frame 11402 differs from the frame 11202 in that the frame 11402 includes an opening 11428 throat 11428 along the bottom of the base 11404. The opening 11428 throat 11428 leads to a throat 11430 opening 11431 that extends along the length of the frame 11402. The throat 11430 opening 11431 can be used to interface with clamps, accessories, and other features to create a connection between the frame 11402 and these other features. Examples of these features will be discussed in other sections below. To define the throat 11430 opening 11431, the frame 11402 includes an interior sidewall 11432. As shown in the figures, the interior sidewall 11432 generally takes the shape of a square with an open face for the opening 11428 throat 11428. However, other shapes can be considered and used as long as the overall functionality of the frame 11402 is maintained. For example, the interior sidewall 11434 can be trapezoidal or triangular in shape. In other examples, the interior sidewall 11434 can have more rounded edges and sidewalls than shown in the figures. A first leg 11410A extends upward from the interior sidewall 11432. As shown in the figures, the first leg 11410A extends from about the midpoint of the interior sidewall 11432, but the first leg 11410A can extend from other portions of the interior sidewall 11432 as long as the first leg 11410A properly supports the panel support surface 11418 and properly forms the clamp cavity 11412. The clamp cavity 11412 is formed between the first leg 11410A and an outer lip 11408. The outer lip 11408 extends from a side of the interior sidewall 11432 and eventually extends parallel to the length of the first leg 11410A to form the clamp cavity 11412. The arrangement of the outer lip 11408 and the interior sidewall 11432 define an angled edge 11434 proximate the bottom of the frame 11402.

[0357] As Figure 115As shown in FIG. 114, the frame 11402 can include clamping jaws 11436A, 11436B. The clamping jaws 11436A, 11436B extend into the throat 11428 of the opening 11428 from opposite sides of the throat. The first clamping jaw 11436A extends into the throat 11428 of the opening 11428 from a portion of the frame proximate the angled edge 11434, and the second clamping jaw 11436B extends into the throat 11428 of the opening 11428 from the base 11404 on an opposite side of the throat 11428 of the opening 11428. The clamping jaws 11436A, 11436B are used to further secure portions of clamps and other accessories to the frame 11402 by providing engagement surfaces to which the clamps and other accessories can be connected. The clamping jaws 11436A, 11436B can take different shapes and form different angles relative to the throat 11430 opening 11431 and interior sidewall 11432 to facilitate these connections. As Figure 116 As shown in FIG. 114, the frame 11402 is formed from rolled steel in a similar manner as described in International Application Publication No. 2024 / 097312, which is incorporated by reference herein in its entirety.

[0358] Accessories for additional module frames

[0359] Reference Figures 117-125 FIG. 117 shows an intermediate clamp 11700 for use with the frames 11402, 116020. The clamp 11700 includes a top portion 11702, an intermediate portion 11704, and a base 11706. The top portion 11702, the intermediate portion 11704, and the base 11706 are aligned along an axis A17. Fasteners 11708 are used to secure the top portion 11702, the intermediate portion 11704, and the base 11706 together and are also aligned along the axis A17. The connection between the fasteners 11708 and the other elements of the clamp 11700 will be discussed in more detail below.

[0360] As Figures 117-120 As shown in FIG. 117, the top portion 11702 includes a body 11710, which is generally cuboid in shape as shown in the figure. The body 11710 can take other shapes so long as the function of the clamp 11700 is maintained. Mounting lips 11712A, 11712B extend from the top of the body 11710. The mounting lips 11712A, 11712B extend outwardly in opposite directions from the body 11710 in a direction perpendicular to the axis A17 of the clamp 11700. Like other mounting lips discussed in this disclosure, the mounting lips 11712A, 11712B are configured to engage corresponding lips and cavities on a solar panel frame to secure the frame to the clamp 11700.

[0361] A slot 11714 is provided along a top surface of the body 11710, extending perpendicular to the axis A17 and parallel to the mounting lips 11712A, 11712B. In a central portion of the body 11710, a recess 11716 extends slightly into the body 11710 along the slot 11714. Within the recess 11716, a hole 11718 extends through the body 11710. The hole 11718 is arranged to receive the fastener 11708 therein. The hole 11718 can be threaded to facilitate engagement with the fastener 11708, or the hole 11718 can be unthreaded to enable some rotation of the top portion 11702 relative to the base 11706. Such rotation can facilitate installation of the clamp 11700, as will be discussed in more detail below. The body 11710 also defines a hollow 11720 extending from the bottom surface into the body 11710. The hollow 11720 is accessible only from the bottom surface, and is configured to accept the mating walls 11732A, 11732B (which are part of the middle portion 11704) and the channel portion 11742 (which is part of the base 11706). Such engagement facilitates alignment and connection between the top portion 11702, the middle portion 11704, and the base 11706.

[0362] As Figure 117 , 118As shown in FIGS. 121 and 122, the middle portion 11704 includes a main body 11722. The main body 11722 defines alignment flanges 11724A, 11724B and clamp support wings 11726A, 11726B. The alignment flanges 11724A, 11724B extend from opposite sides of the main body 11722, and the clamp support wings 11726A, 11726B extend from the other two sides of the main body 11722 that are also opposite each other. The alignment flanges 11724A, 11724B can be used to arrange and secure the clamp 11700 inside the rail R, which will be discussed in more detail below. The clamp support wings 11726A, 11726B include flat portions 11728A, 11728B that extend straight in an outward direction. The clamp support wings 11726A, 11726B terminate in extensions 11730A, 11730B that extend upward from the ends of the flat portions 11728A, 11728B. The extensions 11730A, 11730B include vertical edges 11731A, 11731B that extend directly upward from their respective flat portions 11728A, 11728B. The extensions 11730A, 11730B also include angled edges 11733A, 11733B that extend between their respective flat portions 11728A, 11728B and their respective vertical edges 11731A, 11731B to define an acute angle between the flat portions 11728A, 11728B and the vertical edges 11731A, 11731B. In other embodiments, the extensions 11300A, 11300B can be rounded. The extensions 11730A, 11730B are shaped to fit within the opening 11428 throat 11428 and the throat 11430 opening 11431 of the module frame 11402. During installation of the module frame 11402, audible and tactile feedback is provided when the extensions 11730A, 11730B enter the opening 11428 throat 11428 and come into contact with the base 11404 and / or the interior sidewall 11432. In the embodiment of the frame 11402 shown in FIG. 149, audible and tactile feedback can also be generated between the extensions 11730A, 11730B and the detents 11436A, 11436B. In further embodiments, the extensions 11730A, 11730B can be shaped to fit around or be secured against the detents 11436A, 11436B to further facilitate the connection between the clamp 11700 and the frame 11402. Such a connection also helps to prevent the module 11430 from shifting, and such a connection also helps to ensure that the module frame 11430 is properly aligned within the array when it is installed to the clamp 11470. Figure 115 In the embodiment of the frame 11402 shown in FIG. 149, audible and tactile feedback can also be generated between the extensions 11730A, 11730B and the detents 11436A, 11436B. In further embodiments, the extensions 11730A, 11730B can be shaped to fit around or be secured against the detents 11436A, 11436B to further facilitate the connection between the clamp 11700 and the frame 11402. Such a connection also helps to prevent the module 11430 from shifting, and such a connection also helps to ensure that the module frame 11430 is properly aligned within the array when it is installed to the clamp 11470.

[0363] The alignment flanges 11724A, 11724B and the clamp support wings 11726A, 11726B at least partially define an opening 11732 extending through the body 11722. The opening 11732 is shaped to receive the passage portion 11742 of the base 11706 therethrough. As shown in the figures, the opening 11732 is rectangular, but other shapes can be used so long as they can receive the passage portion 11742. The mating walls 11734A, 11734B also define the opening 11732. The mating walls 11734A, 11734B extend vertically upward from the body 11722 perpendicular to the alignment flanges 11724A, 11724B and the clamp support wings 11726A, 11726B. The mating walls 11734A, 11734B are configured to be received within the hollow 11720 of the top portion 11710 to connect the middle portion 11704 to the top portion 11710. As shown in the figures, the mating walls 11734A, 11734B are C-shaped, with the mating wall 11734A presenting a forward C-shape and the mating wall 11734B presenting a reverse C-shape. However, the mating walls 11734A, 11734B can take other shapes so long as they can be securely received within the hollow 11720 of the top portion 11702. A portion of each mating wall 11734A, 11734B extends along the length of its respective clamp support wing 11726A, 11726B, and the other two portions partially extend along the length of the opposing alignment flanges 11724A, 11724B.

[0364] As Figure 117 , 118As shown in FIGS. 123 and 124, the base 11706 includes a body 11736. Base wings 11738A, 11738B extend from opposite sides of the body 11736. The ends of the base wings 11738A, 11738B define slots 11740A, 11740B. The slots 11740A, 11740B are shown as having a uniform depth, rather than being arcuate as they are shown in the base 2206. However, it is contemplated that the slots 11740A, 11740B of the clamp 11700 can be arcuate, including the same benefits and features as the slots 2240A, 2240B of the clamp 2200. The slots 11740A, 11740B are configured to engage portions of the track R to further stabilize the rotary clamp 2200 within the track R. Examples of these portions can be corresponding grooves or channels within the track R such that the base 11706 can act as a channel nut within the track R. Channels 11742 extend upwardly from the base wings 11738A, 11738B. The channels define holes 11744 that are configured to receive fasteners 11708 to connect the top portion 11702 to the base 11706. The holes 11744 can be threaded to further secure the fasteners 11708.

[0365] Similar to the clamp 2200 discussed above, the clamp 11700 fits within the track R. In a first method of installation, the clamp 11700 is aligned with the ends of the track R such that the base wings 2238A, 2238B are aligned within the grooves G and the clamp support wings 2226A, 2226B are aligned on top of the support surfaces S. This enables the clamp 11700 to be slid along the track R to be placed in position at its desired location. In a second method of installation, the clamp 11700 can be angled to slide into the top opening in the track R from a vertical orientation. The alignment flanges 11724A, 11724B and the base wings 11738A, 11738B are shaped to rotate within the track R and fit within their respective grooves G and against their respective support surfaces S to be placed in their desired locations.

[0366] When the clamp 11700 is in its desired location, the first module frame 11402 is slid into position against the clamp such that the clamp cavity 11412 receives the first mounting lip 11712A and the opening 11430 receives the extension 11730. After the first clamp 11700 is slid into position, the second clamp 11700 can be rocked into position such that the second extension 11730B is received within the opening 11430 and throat 11428 of the second frame 11402 and the second mounting lip 11412B is received and engaged within the clamp cavity 11412.

[0367] In another example, the first module frame 11402 can be shaken and / or rotated into position. When this occurs, the first frame 11402 is rotated like the other frames 102, 202, 302, 402 so that the outer lip 11408 moves upward relative to the rail R and the opening 11428 throat 11428 and the throat 11430 opening 11431 receive the first extension 11730A. Then, the frame 11402 is rotated downward toward the rail R so that the clip cavity 11416 engages the first mounting lip 11712A. When this occurs, the base 11404 is in full contact with the top surface of the rail R and the extension 11730A is fully received within the throat 11430 opening 11431.

[0368] In both examples, after the first clip 11700 is shaken into position, the second clip 11700 can be shaken into position in the same manner so that the second extension 11730B is received within the opening 11428 throat 11428 and the throat 11430 opening 11431 of the second frame 11402 and the second mounting lip 11412B is received and engaged within the clip cavity 11412.

[0369] To disengage the clip 11470 from the frame 11402, the fastener 11708 is loosened so that the top portion 11702 can be loosened or removed, which disengages the mounting lips 11712A, 11712B from their clip cavities 11412.

[0370] In some cases, the clip 11700 can be pre-assembled prior to use, meaning that the fastener 11708 is disposed tightly against the top portion 11702. In this case, the clip 11700 is considered a tool-less clip, meaning that no tool is needed to attach the clip 11700 to the rail R and the frame 11402. In other cases, the fastener 11708 can not be fully tightened against the top portion 11702 and the base 11706. After installation, the fastener 11708 can be tightened to further secure the connection between the mounting lips 11712A, 11712B and their respective frames 11402.

[0371] Referring to Figure 125 , the frame 11402 is shown with a modified skirt assembly 6000'. The skirt assembly 6000' is nearly identical to the skirt assembly 6000 shown in FIGS. 60-65. However, the base 6002' includes an extension 6003' that engages with the opening 11431 and / or the detents 11436A, 11436B of the frame 11402.

[0372] Referring to Figure 126 and 127wire holder 12602, an elongated body 12604, and a securing extension 12606. The wire holder 12602 holds and organizes the wire W against the frame 11402. The wire holder 12602 includes a first side wall 12608, a second side wall 12610 opposite the first side wall 12608, and a connecting portion 12612 extending between and connecting the first side wall 12608 and the second side wall 12610. The first side wall 12608, the second side wall 12610, and the connecting portion 12612 define a wire holding space 12614 therein. The first side wall 12608 extends along the second leg 11410B of the frame 11402 and terminates in a bend 12611 bent away from the second leg 11410B. The second side wall 12610 extends generally parallel to the second leg 11410B without the bend 12611 of the first side wall 12608. In other embodiments, the second side wall 12610 can include its own bend portion, or the side walls 12608, 12610 can take different shapes, so long as the wire W can be held within the holding space 12614. The entire wire holder 12600 can also take different shapes from the shape shown, so long as the wire holder 12600 can be secured to the frame 11402 and hold the wire W therein.

[0373] The elongated body 12604 extends from a corner defined between the second side wall 12610 and the connecting portion 12612. The elongated body 12604 includes a first straight portion 12618 extending along a top of the base 11404, a curved portion 12618 wrapping around an end of the base 11404, a second straight portion 16222 extending along a bottom of the base 11404, and an angled portion 12624 extending away from the second straight portion 16222 in a direction away from the base 11404. The angled portion 12624 extends away from the second straight portion 16222 and the base 11404 at a non-perpendicular angle.

[0374] The fixed extension 12606 extends upward from the angled portion 12624 in a direction toward the frame 11402. The fixed extension 12606 includes an upward extending portion 12626 and a downward extending portion 12628. The upward extending portion 12626 extends through the throat 11428 opening 11428 and into the throat 11430 opening 11431 so that it contacts a portion of the circular sidewall 11432. As shown in the figure, the upward extending portion 12626 contacts a corner of the sidewall 11432. The downward extending portion 12628 extends in an opposite direction from the upward extending portion 12626. The contact between the upward extending portion 12626 and the circular sidewall 11432 enhances the connection between the wire dispenser 12600 and the frame 11402. The downward extending portion 12628, when contacted, can act as a lever to displace the upward extending portion 12626. This is done to facilitate the removal of the upward extending portion 12626 from the throat 11430 opening 11431 in order to remove the wire dispenser 12600 from the frame 11402. This can also be done to bend the upward extending portion 12626 so that it can fit into the throat 11430 opening 11431 during the installation of the frame 11402. In the case where the frame 11402 has detents 11436A, 11436B, the wire dispenser 12600 can include a press portion 12630 that contacts the first detent 11436A to further connect the wire dispenser 12600 to the frame 11402, but the fixed extension 12606 can extend in a different direction as long as its engagement with the frame 11402 remains the same. In view of the nature of the engagement of the wire dispenser 12600 around the frame 11402, the wire dispenser 12600 can be made of a bendable or elastic material. This enables the wire dispenser 12600 to engage, disengage, and be reused against the frame 11402.

[0375] Referring to Figure 128 and 129 , another wire dispenser 12800 for the frame 11402 is shown. The wire dispenser 12800 is made of a bendable, elastic material, such as sheet metal, rolled steel, or plastic. This enables the wire dispenser 12800 to be bent and curved in multiple positions to fit around the frame 11402 and define a wire holding space 12803 with the frame 11402. This also enables the wire dispenser 12800 to "snap" into place against the frame 11402 and be easily removed and replaced against the frame 11402.

[0376] Wire dispenser 12800 includes a wire retaining section 12802, an elongate body 12804, and a tail 12806. Wire retaining section 12802 is shaped to engage with first leg 11410A and outer lip 11408 to define a wire retaining space 12803 with these features and clip cavity 11418. To this end, wire retaining section 12802 includes an angled side wall 12808 having an end that contacts first leg 11410A. Angled side wall 12808 extends at a non-ninety degree angle from first leg 11410A. A curved top 12810 extends from angled side wall 12808 and is a distance above clip cavity 11418. A lip side wall 12812 extends from curved top 12810 and extends down along the outside of lip 11408. A portion of first leg 11410A, angled side wall 12808, curved top 12810, a portion of lip side wall 12812, and a portion of outer lip 11408 define wire retaining space 12803. Within this space, wire W can be organized relative to frame 11402. In some embodiments, some wire W can be retained within clip cavity 12812. The shape of wire retaining section 12802 around clip cavity 11412 and its contact with first leg 11410A creates a spring force that helps secure wire dispenser 12800 to frame 11402.

[0377] An elongated body 12804 extends from the bottom end of the lip sidewall 12812. The elongated body 12804 includes a base wall 12814, a bend portion 12816, and a rounded bottom wall 12818. In particular, the base wall 12814 extends from the end of the lip sidewall 12812 along the bottom of the frame 11402 against the throat 11428 and base 11404 of the opening 11428. The throat extension 12816 protrudes upward from the base wall 12814 and extends into the throat 11430 opening 11431. The bend portion 12816 extends from the base wall 12814 and bends so that the rounded bottom 12820 extends below the frame 11402. As shown, the bend portion 12816 includes a first bend, a vertex, and a second bend, defining an open triangle from which the rounded bottom 12820 extends. However, the bend portion 12816 can take on different shapes, such as an open square or a semicircle, so long as the overall shape and function of the wire dispenser 12800 is maintained. The rounded bottom wall 12820 curves downward away from the frame 11402. The tail 12806 extends upward from the end of the rounded bottom wall 12820 back toward the frame 1140. In particular, the vertical wall 12822 extends straight toward the frame 11402, and the everted portion 12824 extends from the end of the vertical wall 12822 at a non-ninety degree angle as shown. Those skilled in the art will appreciate that these features can take on other shapes and angles and still maintain their function as described herein.

[0378] Toolless mounting clip

[0379] Reference Figures 130-168 FIGS. 1-8 illustrate different embodiments of toolless mounting clips. These clips include similar features with similar functions. Those skilled in the art will understand the manner in which one or more of these toolless clips operate based on the description of similar clips. Each clip will be described in conjunction with a rail R, Rl, R2. In some cases, the engagement of the clip with its respective rail R, Rl, R2 will be similar, and those of ordinary skill in the art will appreciate that certain clips can be used with one or more of the rails R, Rl, R2 described herein.

[0380] Certain elements of the toolless clips will be described using directional terms such as up, down, left, and right. These terms will be described relative to the rail R, Rl, R2 on which the clip will be mounted.

[0381] Reference Figures 130-133BFig. 1 1 shows a first one-piece intermediate clamp 13000. The clamp 13000 can be made of sheet metal or another resilient material for use in the manner described herein. The clamp 13000 includes a generally square-shaped body 13002. Mounting lips 13004A, 13004B extend from opposite sides of the body 13002 and are arranged to fit into the clamp cavities 1 12, 212, 312, 412, 1 1412 of the module frames 102, 202, 302, 402, 1 1402. Legs 13006A, 13006B extend from two other opposite sides of the body 13002. The legs 13006A, 13006B extend downward in a direction generally perpendicular to the direction of the mounting lips 13004A, 13004B, in a direction toward the rail R. The legs 13006A, 13006B terminate in clips 13008A, 13008B. The clips 13008A, 13008B are shaped to engage the outer edge El of the rail Rl. The legs 13006A, 13006B are made of resilient metal so that they can be bent outward and snap into place against the outer edge El of the rail Rl. The legs 13006A, 13006B are also rigid enough to hold the clamp 13000 in place against the rail Rl. Figures 133A-133B An example of the mounting process for the clamp 13000 and two frames 102 is shown. The first frame 102 is placed on the rail Rl and the clamp 13000 is placed in position next to the frame 102. This is done by pushing the clamp 13000 downward so that the clips 13008A, 13008B are pushed outward by the edge El of the rail Rl so that eventually the edge El is received within the clips 13008A, 13008B. In this process, the clips 13008A, 13008B are snapped back into place. Thus, the legs 13006A, 13006B are released so that the clips 13008A, 13008B snap into place against the edge El, thereby securing the clamp 13000 to the rail Rl. The clamp 13000 is then slid along the rail Rl so that the mounting lip 13006A engages the clamp cavity 1 12. Then, the second frame 1 12 is rocked into position so that the clamp cavities 1 12, 212, 312, 412 of the second frame 1 12 engage the second mounting lip 13004B of the clamp 1300.

[0382] In another example, the clip 13000 can be secured at a point along the track Rl such that the first mounting lip 13006A engages the clip cavity 112, 212, 312, 412 of the frame 102 when the legs 13006A, 13006B engage the track Rl and the clips 13008A, 13008B snap onto the track edges. In yet another example, the clip 13000 can be secured against the track Rl first, and then the frame 102 is rocked and / or rotated into position to engage the clip cavity 112, 212, 312, 412 with the mounting lip 13006A. In both examples, the second frame 112 is rocked and / or rotated into position against the second mounting lip 13006B such that the clip cavity 112, 212, 312, 412 engages the lip 13006B. In each example provided herein, the individual frame 112 can be removed from the clip 13000 by rotating the frame 112 in a direction opposite the mounting direction. To remove the clip 13000, the legs 13006A, 13006B are pulled away from the track Rl such that the clips 13008A, 13008B disengage their respective edges El, and the clip 13000 can be removed.

[0383] Referring to Figures 134-135 A second one-piece intermediate clip 13400 is shown in FIG. 34. The clip 13400 can also be made of sheet metal or another resilient material. The clip 13400 has a body 13402 with mounting lips 13404A, 13404B extending from opposite sides. Legs 13406A, 13406B extend from the other two opposite sides of the body in a direction perpendicular to the mounting lips 13404A, 13404B toward the track. The legs 13406A, 13406B terminate in clips 13408A, 13408B that are shaped to engage the edges El of the track Rl. The legs 13406A, 13406B also include wings 13410A, 13410B that first extend partially upward in a direction away from the track Rl and then are folded to extend downward toward the track Rl. The wings 13410A, 13410B provide resiliency to the legs 13406A, 13406B that enables the clip 13000 to be held in position against the track Rl. The mounting of the clip 13400 and the associated module frame 102 is the same as described above in connection with the clip 13000.

[0384] Referring to Figures 136-138Figure 13B, showing a two-piece intermediate clamp 13600. This clamp 13600 includes a module engaging portion 13602 and a separate rail engaging portion 13604 connected by fasteners 13606. The module engaging portion 13602 includes a body 13610 defining holes 13611 for receiving fasteners 13608. Mounting lips 13612A, 13612B extend from opposite sides of the body 13610 for engaging a solar panel frame to be mounted to the clamp 13600. Notches 13614A, 13614B are formed in the other two opposite sides of the body 13610 to provide space for wings 13622A, 13622B of the rail engaging portion 13604. The rail engaging portion 13604 includes a body 13616 defining holes 13618 aligned with the holes 13610. This alignment enables the module engaging portion 13602 to be secured to the rail engaging portion 13616 by the fasteners 13606. Legs 13620A, 13620B extend from the body 13616 and form wings 13622A, 13622B over the body 13616 in a direction away from the rail Rl. The wings 13622A, 13622B self-fold over and then extend downward in a direction toward the rail Rl and terminate in clips 13624A, 13624B configured to engage the edge El of the rail Rl. The use of the clamp 13600 is the same as the clamp 13400 discussed above. This two-piece embodiment 13600 has the advantage of easily removing the module engaging portion 13602 to facilitate removal of a single module within the array.

[0385] Referring to Figures 139-141, showing a spring clip 13900. Like the previous tool-less clip, the spring clip 13900 can be made of sheet metal or another resilient material to facilitate its installation to and removal from the rail Rl. The spring clip 13900 includes a body 13902 having mounting lips 13904A, 13904B extending from opposite sides of the body, with the mounting lips 13904A, 13904B extending from opposite sides. Legs 13906A, 13906B extend from two other opposite sides of the body in a direction perpendicular to the mounting lips 13904A, 13904B toward the rail. The legs 13906A, 13906B include tabs 13908A, 13908B that are deflected inward in a direction toward the rail R. The tabs 13908A, 13908B terminate at ends 13910A, 13910B that are configured to engage the underside Ul of the edge El of the rail Rl. The engagement between the ends 13910A, 13910B and their respective underside Ul creates a wedging effect that helps to secure the legs 13906A, 13906B in place to attach the clip 13900 to the rail R. The deflection of the tabs 13908A, 13908B separates the legs 13906A, 13906B so that struts 13912A1, 13912A2, 13912B1, 13912B2 are defined on opposite sides of the tabs 13908A, 13908B, and gaps 13914A, 13914B are defined between the respective pairs of struts 13912A1, 13912A2, 13912B1, 13912B2. The legs 13906A, 13906B define openings 13916A, 13916B above the tabs 13908A, 13908B and the gaps 13914A, 13914B. Bridge portions 13918A, 13918B extend across the legs 13906A, 13906B and separate the openings 13916A, 13916B from the gaps 13914A, 13914B. The bridge portions 13918A, 13918B are used to secure a spring element 13920 between the rail Rl and the body 13902 on the underside of the body 13902.

[0386] Spring elements 13920 are provided to further secure the spring clip 13900 to the track R1 and to hold the spring clip 13900 in an upright position to enable installation of the second module frame 102. The spring elements 13920 are secured to the bridge portions 13918A, 13918B at ends 13922A, 13922B. The ends 13922A, 13922B are shaped to hook around the bridge portions 13918A, 13918B. Inward from the ends 13922A, 13922B are concave portions 13924A, 13924B which are rounded so that they contact the top of the edge El and hook around the track bridge portions 13918A, 13918B. The concave portions 13924A, 13924B then transition to convex portions 13926 at the center of the spring element 13920. The top of the convex portions contact the underside of the body 13902. The contact between the top of the edge El and the underside of the body 13902 enables the spring elements 13920 to support the clip 13900 in place against the track R. The spring elements 13920 are also made of a resilient material to provide a spring force against the body 13902 and the top of the edge El. Installation and removal of the clip 13900 is the same as the tool-less clip already described.

[0387] Referring to Figures 142-145C , a two-piece end clip 14200 is shown. The two-piece end clip 14200 includes a module engagement portion 14202 and a track engagement portion 14204 connected by a fastener 14206 having threads to facilitate connection between the two portions 14202, 14204. The module engagement portion 14202 includes a body 14208 defining a threaded hole 14216 for receiving the fastener 14206. The body 14208 has a flat lower surface arranged to rest on the top of the edge El of the track R1. Only a single mounting lip 14212 extends upward from one side of the body 14208 and is arranged to engage with the clip cavity 112, 212, 312, 412 of the module frame 102. The other side of the body 142008 is free of mounting lips. The track engagement portion 14204 includes a body 14214 defining a hole 14216 configured to align with the hole 14210 in the module engagement portion 14202 to receive the fastener 14206. Mounting ends 14218A, 14218B extend from opposite ends of the body 14214. When the clip 14200 is fully installed, the mounting ends 14218A, 14218B are arranged to engage with the inner edge E3 of the track R so that engagement of the body 14208 with the top of the edge El secures the clip 14200 to the track R as shown in Figure 145C .

[0388] Referring toFigures 145A-145C The installation method for the two-piece end clip 14200 will now be described. First, the rail engaging portion 14204 is secured to the bottom of the fastener and aligned with the module engaging portion 14202 such that one of the mounting ends 14218A, 14218B extends in the same direction as the mounting lip 14212. This is shown in Figure 145A . The clip 14200 is then placed down into the rail Rl until the bottom surface of the body 14208 contacts the top edge El of the rail Rl. Thereafter, the fastener 14206 is rotated until the mounting ends 14218A, 14218B engage and are tightened against the inner edge E3 of the rail to secure the rail engaging portion 14204 into place. This is shown in Figure 145B and 145C . At this point, the frame 102, 202, 302, 402, 14000 can be rocked into place against the mounting lip 14212. The clip 14200 can also be secured into place along the rail R of the frame 102 that already exists to secure the clip 14200 by engaging the mounting lip 14216 with the clip cavity 112.

[0389] Referring to Figure 146 and 147 , a one-piece top clip 14600 is shown. The operation of the one-piece top clip 14600 is similar to the first and second one-piece middle clips 13000, 13400. However, the legs 14606A, 14606B are longer such that the mounting lips 14604A, 14604B are disposed at a higher location above the rail R2 and have a bent corner to provide additional gripping engagement against the installed module frame SF. This enables the installation of a standard module frame SF between the mounting lips 14604A, 14604B and the rail R2 with the mounting lips 14604A, 14604B engaging the top surface of the standard module frame SF. The legs 14606A, 14606B also narrow in the direction toward the rail R2 to enable rocking of the standard module frame SF. The mounting lips 14604A, 14604B can be flatter than the previously described mounting lips to facilitate this engagement. The mounting lips 14604A and / or the body 14602 can have a sharp edge disposed along its length to engage with the module frame SF when installing it. The rail R2 can also contain a flat surface across the outer edge E2 to support the module frame SF.

[0390] Referring to Figures 148-150The diagram shows a two-piece top clamp 14800. The operation of the two-piece top clamp 14800 is similar to that of the two-piece clamp 13600. However, the legs 14806A and 14806B are longer, allowing the mounting lips 14804A and 14804B to be positioned higher above the track R2. Like the one-piece top clamp 14600, the two-piece top clamp 14800 engages with the standard modular frame SF. The modular engagement portion 14802 includes a notch 14280 to increase the strength of the component. The mounting lips 14804A and 14804B are also bent downwards to provide a counter-rotational force between the modular engagement portion 14802 and the track engagement portion 14804.

[0391] refer to Figures 151-155B Another one-piece clamp 15100 is shown. This clamp 15100 is also made of metal, but can be formed by metal casting. The one-piece clamp 15100 includes a top portion 15102, a neck 15104, and a base 15106. The top portion 15102 includes a body 15108 having hollow portions 15110A and 15110B, which are provided to reduce the overall weight of the clamp 15100. Mounting lips 15112A and 15112B extend from opposite sides of the top of the body 15108 to engage with solar panel frames 102, 202, 302, and 402, as discussed herein. End walls 15114A and 15114B extend downward in a direction toward the track R from opposite sides of the body 15108 adjacent to the side having the mounting lips 15112B. End walls 15114A and 15114B may contact the top surface R1 of the track R to arrange the clamp 15100 along the track R or to provide support against the track R, and to ensure that the second module frame 102 can be mounted to the clamp 15100. End walls 15114A and 15114B and neck 15104 define clearances 15116A and 15116B.

[0392] The neck 15104 connects the top portion 15102 and the base 15160 and extends along a central portion of the clamp 15100. The base 15160 includes a body 15118 having base wings extending from opposite sides of the body 15160. The ends of the base wings 15120A, 15120B define slots 15122A, 15122B configured to engage with portions of the rail R to further stabilize the clamp 15100 within the rail R. As discussed above in connection with the clamps 2200, 11700, the base wings 15120A, 15120B can extend into the groove G defined on the interior of the rail. Like the clamps 2200, 11700, the clamp 15100 can be slid into the end of the rail and along the length of the rail until it is placed at its desired location. The clamp 15100 can also be pressed into the rail R via the top opening and aligned after it is inside the rail R. The clamp 15100 can then be engaged with the solar panel module 102, 202, 302, 402, 11402, 11602.

[0393] Referring to Figures 156-158 A two-piece clamp 15600 is shown. This clamp 15600 is also made of metal and can be formed by metal casting. The clamp 15600 includes a top portion 15602 and a base 15604, with a fastener 15606 connecting the two elements. Because this clamp 15600 is made of two pieces, it can be removed from the middle of a solar panel array by disconnecting the fastener 15606 and removing the top portion 15602. This enables the removal of adjacent solar panel modules.

[0394] The overall shape of the clamp 15600 is similar to the clamp 15100, with mounting lips 15614A, 15614B and end walls 15616A, 15616B extending from the body 15608 of the top portion 15602. The top portion 15602 defines a recess 15610 from which a hole 15612 extends through the top portion 15602. The hole 15612 is aligned with a corresponding threaded hole 15622 in the base 15604. The holes 15612, 15622 are connected with the fastener 15608. The base 15604 also includes base wings 15624A, 15624B and base slots 15626A, 15626B to facilitate engagement with the rail R. The clamp 15600 can also be entered into the rail R from above and twisted after the base 15606 is inside the rail R, engaging the base wings 15624A, 15624B with the groove G in the rail R.

[0395] Referring to Figures 159-162Figure 17, showing a three-piece clamp 15900. The clamp 15900 has a top portion 15902, a middle portion 15904, and a base 15906. The top portion 15902, the middle portion 15904, and the base 15906 are aligned along an axis (common axis A15), and fasteners 15908 are used to secure the elements together. The arrangement of this clamp is similar to the other clamps 2200 [numbering of rotary clamps] discussed above.

[0396] The top portion 15902 includes a body 15910 having a centrally located notch 15912. A hole 15914 is formed in the notch and extends through the body 15910 for securing the top portion 15902 to the base portion 15906. Mounting lips 15916A, 15916B extend from opposite sides of the body 15910. Suspension walls 15918A, 15918B extend downward from the underside of the body 15910 toward the track R proximate the mounting lips 15916A, 15916B. The suspension walls 15918A, 15918B define a mating space 15920 to receive the mating walls 15926A, 15926B of the middle portion 15904.

[0397] The middle portion 15904 includes a body 15920 that defines an alignment flange 15924 extending around the perimeter of the body. The alignment flange 15924 is configured to engage with a feature on the track R, such as the support surface S. The body 15920 also includes mating walls 15926A, 15926B that extend upward in a direction perpendicular to the alignment flange 15924 toward the top portion 15920. The mating walls 15926 are shaped and sized to fit within the mating space 15920 to further secure the middle portion 15904 to the top portion 15902. The mating walls 15926 and the alignment flange 15924 define an opening 15928 through which the channel 15932 of the base 15906 extends.

[0398] The base 15906 includes a main body 15930. A channel portion 15932 extends from the main body 15930 and defines a hole 15934 that receives the fastener 15908 therethrough. The hole 15934 can be threaded to facilitate such engagement. The hole 15934 is aligned with the hole 15914 in the top portion 15902 to secure the top portion 15902 to the bottom portion 15906. The mating wall 15926 of the middle portion 15904 extends around the channel portion 15932 and is configured to be arranged in alignment against the channel portion 15932 when the channel 215932 extends through the opening 15928. Like the base previously discussed, the base 15906 includes a base wing 15936 and a base slot 15936 that are configured to fit within and engage with the slot G in the track R. The clamp 15900 is installed by sliding the base wing 15936 into the slot G and sliding the alignment flange 15924 over the support surface S, and moving the clamp 15900 into its desired position on the track. The clamp 15900 can also be accessed into the track R from the top opening and rotated until these engagements with the slot G and support surface S are made.

[0399] Reference Figures 163-167 is shown. The end clamp 16300 includes many of the same features as the clamp 15900, but there is only one mounting lip 16916. There are three downward facing side walls 16318A, 16318B, 16318C that extend from the other sides of the base 16306 of the top portion 16302. Two of the side walls 16318A, 16318C are angled inward in a direction toward the middle portion 16304 and the base 16306. This enhances the strength of the top portion 16302 and acts as a stop for the outer lip 108 on the module frame 102 near the mounting lip 16316. The third side wall 16318B, which is located on the side opposite the mounting lip 16316, extends straight downward toward the track R and folds inward toward the rest of the clamp 16300 so that the portion that extends toward the clamp 16300 contacts and rests against the top surface S of the track R. The fasteners 16308 connect the top portion 16302 to the bottom portion 16306 through respective holes 16314, 16334, which are threaded. The installation and removal of this clamp 16300 relative to the track R is the same as the clamp 15900 described above.

[0400] Congratulations, you have completed the application!

[0401] While specific embodiments of the devices of the present disclosure have been described in detail, those skilled in the art will appreciate that various modifications and alternatives to those details could be developed in light of the overall teachings of the present disclosure. Accordingly, the particular arrangements disclosed are meant to be illustrative only and not limiting as to the scope of the devices of the present disclosure which is to be given by the following claims as construed according to the principles of patent law, including all equivalents of the claims. It is also to be understood that the various features of the different embodiments disclosed herein can be combined and used together in any combination without departing from the scope of the present disclosure.

Claims

1. A frame for a photovoltaic module, the frame comprising: The base portion includes an outer lip and a bottom surface, and the base portion defines an opening configured to receive a first mounting element therein; At least one leg extending from the base portion; as well as A panel support portion extending from the at least one leg, the panel support portion being configured to secure the solar panel to... in, The outer lip and the at least one leg define a cavity.

2. The framework according to claim 1, wherein, The base portion further includes a circular sidewall extending between the bottom surface and the outer lip, the circular sidewall defining the opening.

3. The framework according to claim 2, wherein, The at least one leg extends from the midpoint of the circular sidewall.

4. The framework according to claim 1, wherein, The base portion further includes at least one latch that extends at least partially into the opening.

5. The framework according to claim 4, wherein, The at least one chuck includes two chucks, and The two claws extend from opposite sides into the opening.

6. The framework according to claim 3, wherein, The at least one leg includes a first leg and a second leg. Wherein, the first leg extends from the midpoint of the circular sidewall, and The second leg extends from the portion of the base portion near the circular sidewall.

7. The framework according to claim 1, wherein, The cavity is configured to receive a second mounting element therein.

8. The framework according to claim 7, wherein, The first mounting element and the second mounting element are parts of the mounting fixture.

9. A frame installation component, comprising: The framework according to claim 8; as well as A mounting fixture, configured to mount the frame to a track, the mounting fixture comprising: A base, the base being configured to be at least partially fixed to a track; The middle portion is configured to be connected to the base, and the middle portion includes at least one extension configured to be received within the opening; The top portion is configured to connect to the base, and the top portion includes at least one mounting lip configured to be received within the cavity.

10. The frame mounting assembly according to claim 9, wherein, The intermediate portion includes at least one clamping support wing, which extends beyond the base and the top portion by a certain distance in the direction toward the base of the frame, and The extension is located at the end of the clamp support wing.

11. The frame mounting assembly of claim 10, further comprising fasteners, in, The base defines a first hole. The top portion defines the second hole, and The first hole and the second hole are configured to receive fasteners passing through them.

12. The frame mounting assembly according to claim 11, wherein, The intermediate portion includes a body defining a body opening therethrough and a pair of mating walls extending from opposite sides of the body opening. The base includes a channel portion that at least partially defines the first hole, and The channel portion is configured to be received in the opening of the main body.

13. The frame mounting assembly according to claim 12, wherein, The top portion defines a hollow section extending from its bottom side, the hollow section communicating with the second hole, and The hollow portion is configured to receive at least a portion of the pair of mating walls and the channel portion therein.

14. A frame installation component, comprising: The framework according to claim 8; as well as Cable runner, the cable runner comprising: A wire retainer that defines a wire holding space configured to hold a wire therein; An elongated body extending from the wire holder, the elongated body being configured to extend around the base; and A fixed extension extending from the elongated body is configured to extend at least partially into the opening.

15. The frame mounting assembly according to claim 14, wherein, The wire retainer includes a first sidewall, a second sidewall disposed at a certain distance away from the first sidewall, and a connecting portion extending between the first sidewall and the second sidewall. Wherein, at least a portion of the first sidewall is adjacent to the at least one leg of the frame.

16. The frame mounting assembly according to claim 15, wherein, The elongated body extends around the base to secure the wire layer to the frame.

17. The frame mounting assembly according to claim 16, wherein, The elongated body extends a certain distance along the top surface of the base, extends around the edge of the base, and extends a certain distance along the bottom surface of the base.

18. The frame mounting assembly according to claim 17, wherein, The fixed extension includes an upwardly extending portion and a downwardly extending portion. Wherein, the upwardly extending portion extends at least partially into the opening, and The downward extending portion extends in the opposite direction.

19. The frame mounting assembly according to claim 18, wherein, The upwardly extending portion is configured to wedge into the opening, thereby further securing the wire layup to the frame.

20. The frame mounting assembly according to claim 19, wherein, The downward extension is configured to be deflected so that the upward extension disengages from the opening.

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