Solar panel module mounting systems

Abstract

The present disclosure is related to solar panel module mounting systems. The system includes a foot assembly comprising a foot defining a top face and a bottom face, at least a portion of which is configured to contact the mounting surface; a rail configured to be supported on the foot assembly; a base configured to be secured to the foot assembly, the base being configured to connect with at least one attachment mechanism on which a solar panel module is mounted, wherein at least a portion of the top face defines a support surface configured to support an underside of the rail, wherein the foot comprises at least one protrusion, wherein the base comprises at least one attachment tab, and wherein the at least one attachment tab is configured to engage with the at least one protrusion when the base is arranged on top of the rail.

Description

Attorney Docket No. 10089-2505754SOLAR PANEL MODULE MOUNTING SYSTEMSCROSS-REFERENCE TO RELATED APPLICATION

[0001] This application claims priority to U.S. Patent Provisional Application Serial Number 63 / 727,170, filed December 2, 2024, the disclosure of the which is hereby incorporated by reference in its entirety.BACKGROUND OF THE INVENTIONField of the Invention

[0002] The present disclosure relates to ballasted systems for mounting and supporting photovoltaic modules.Description of Related Art

[0003] Photovoltaic modules can be used individually or within large, multiple-module arrays. Some of these systems are used on buildings or other surfaces where space may be limited, creating a need to efficiently organize the modules and safely secure the modules to the surface. Therefore, it is desirable to have ballasted systems that are arranged to allow a user to easily organize the rails of the system in an efficient, spatial manner. Different surfaces also have different load handling capabilities, which makes it desirable to have the ability to have a system that is capable of being arranged in different ways, so that the number of contact points with the surface can be adjusted.SUMMARY OF THE INVENTION

[0004] According to one embodiment or aspect of the present disclosure, a solar panel module mounting system includes a foot assembly for securing a rail to a mounting surface; a rail configured to be supported on the foot assembly; and a base configured to be secured to the foot assembly. The foot assembly includes a foot defining a top face and a bottom face, where at least a portion of the bottom face is configured to contact the mounting surface. The foot also includes at least one protrusion. The rail includes an elongated body; a first side flange extending from a first side of the elongated body; and a second side flange extending from a second side of the elongated body, opposite the first side. At least a portion of the top face defines a support surface configured to support an underside of the elongated body of the rail. The base is configured to connect with at least one attachment mechanism on which a solar panel module is mounted. The base also includes at least one attachment tab. The at least one16959312.DOCXAttorney Docket No. 10089-2505754 attachment tab is configured to engage with the at least one protrusion when the base is arranged on top of the rail.

[0005] In another embodiment or aspect, the foot includes a body defining the top face; and a plurality of mounting lips. The plurality of mounting lips include at least one first mounting lip arranged on a first side of the body and at least one second mounting lip arranged on a second side of the body opposite the first side. The plurality of mounting lips are configured to secure the longitudinal rail to the foot.

[0006] In another embodiment or aspect, the at least one first mounting lip is configured to engage with the first side flange and the at least one second mounting lip is configured to engage with the second side flange.

[0007] In another embodiment or aspect, the at least one first mounting lip includes a first pair of mounting lips and the at least one second mounting lip includes a second pair of mounting lips.

[0008] In another embodiment or aspect, the at least one attachment tab includes two attachment tabs. The at least one protrusion includes two protrusions: a first protrusion arranged between the first pair of mounting lips and a second protrusion arranged between the second pair of mounting lips.

[0009] In another embodiment or aspect, the foot assembly further includes a fastener, and the longitudinal rail defines a rail aperture to receive the fastener therethrough when the rail is supported on the foot assembly.

[0010] In another embodiment or aspect, the base defines a base aperture configured to receive the fastener therethrough when the base is secured to the foot assembly.

[0011] In another embodiment or aspect, the solar panel module mounting system also includes a clip arranged within the base. The clip includes a through hole configured to receive the fastener therethrough; a first elongated aperture arranged on a first side of the through hole; and a second elongated aperture arranged on a second side of the through hole, opposite the first side.

[0012] In another embodiment or aspect, the first elongated aperture and the second elongated aperture are configured to receive a portion of the at least one attachment mechanism therein, when the at least one attachment mechanism is connected to the base.

[0013] In another embodiment or aspect, the through hole has a first portion and a second portion, the first portion having a larger diameter than a width of the second portion and the second portion being elongated.26959312.DOCXAttorney Docket No. 10089-2505754

[0014] In another embodiment or aspect, the portion of the at least one attachment mechanism is configured to move the clip such that the fastener transitions from a first portion of the through hole to a second portion of the through hole when the attachment mechanism is transitioned from a first portion to a second position in relation to the rail.

[0015] In another embodiment or aspect, the second portion of the through hole is flanked by elevated areas.

[0016] In another embodiment or aspect, the base includes a pair of corresponding apertures configured to align with corresponding features of the at least one attachment mechanism.

[0017] In another embodiment or aspect, the at least one attachment mechanism is one of a low side attachment mechanism and a high side attachment mechanism.

[0018] According to one embodiment or aspect of the present disclosure, a solar panel module mounting system includes a plurality of foot assemblies for securing at least one rail to a mounting surface, at least one rail configured to be supported on the plurality of foot assemblies, a plurality of bases, a low side attachment mechanism secured to the first base and configured to rotatably mount a first end of the solar panel module, and a high side attachment mechanism secured to the second base and defining a slot configured to receive a second end of the solar panel module therein. The plurality of foot assemblies each include a foot defining a top face and a bottom face, at least a portion of the bottom faces being configured to contact the mounting surface. The at least one rail includes an elongated body; a first side flange extending from a first side of the elongated body; and a second side flange extending from a second side of the elongated body, opposite the first side. The plurality of bases include a first base secured to a first end of the longitudinal rail; and a second base secured to a second end of the longitudinal rail. At least a portion of the top face defines a support surface configured to support an underside of the elongated body of the at least one rail. The foot includes at least one protrusion. The plurality of bases include at least one attachment tab. The at least one attachment tab is configured to engage with the at least one protrusion when the base is arranged on top of the at least one rail.

[0019] In another embodiment or aspect, the plurality of foot assemblies each include a fastener. The at least one rail defines a plurality of apertures each configured to receive one of the fasteners of the plurality of foot assemblies therethrough. The plurality of bases each define a base aperture configured to receive one of the fasteners of the plurality of foot assemblies therethrough.

[0020] In another embodiment or aspect, the solar panel module mounting system also includes a plurality of clips. The plurality of clips include a first clip arranged within the first36959312.DOCXAttorney Docket No. 10089-2505754 base and a second clip arranged within the second base. Each of the plurality of clips include a through hole configured to receive one of the fasteners of the plurality of foot assemblies therethrough; a first elongated aperture arranged on a first side of the through hole; and a second elongated aperture arranged on a second side of the through hole, opposite the first side.

[0021] In another embodiment or aspect, the first elongated aperture and the second elongated aperture of the first clip are configured to receive a portion of the low side attachment mechanism therein. The portion of the low side attachment mechanism is configured to move the first clip such that the fastener received within the through hole transitions from a first portion of the through hole to a second portion of the through hole.

[0022] In another embodiment or aspect, the first elongated aperture and the second elongated aperture of the second clip are configured to receive a portion of the high side attachment mechanism therein. The portion of the high side attachment mechanism is configured to move the second clip such that the fastener received within the through hole transitions from a first portion of the through hole to a second portion of the through hole.

[0023] In another embodiment or aspect, each one of the plurality of bases includes a pair of corresponding apertures.

[0024] In another embodiment or aspect, the pair of corresponding apertures of the first base are configured to align with a pair of corresponding apertures of the low side connection mechanism. The low side attachment mechanism is configured to rotate about an axis defined by the corresponding apertures of the first base.

[0025] In another embodiment or aspect, the pair of corresponding apertures of the second base are configured to receive portions of the high side attachment mechanism therein, such that the high side mechanism is configured to rotate about the pair of corresponding apertures of the second base.

[0026] The invention according to the present disclosure can be characterized by one or more clauses shown below.

[0027] Clause 1. A solar panel module mounting system comprising: a foot assembly for securing a rail to a mounting surface, the foot assembly comprising a foot defining a top face and a bottom face, at least a portion of the bottom face is configured to contact the mounting surface; a rail configured to be supported on the foot assembly, the rail comprising: an elongated body; a first side flange extending from a first side of the elongated body; and a second side flange extending from a second side of the elongated body, opposite the first side; a base configured to be secured to the foot assembly, the base being configured to connect with at least one attachment mechanism on which a solar panel module is mounted, wherein at least46959312.DOCXAttorney Docket No. 10089-2505754 a portion of the top face defines a support surface configured to support an underside of the elongated body of the rail, wherein the foot comprises at least one protrusion, wherein the base comprises at least one attachment tab, and wherein the at least one attachment tab is configured to engage with the at least one protrusion when the base is arranged on top of the rail.

[0028] Clause 2. The solar panel module mounting system of clause 1, wherein the foot comprises: a body defining the top face; and a plurality of mounting lips comprising at least one first mounting lip arranged on a first side of the body and at least one second mounting lip arranged on a second side of the body opposite the first side, wherein the plurality of mounting lips are configured to secure the longitudinal rail to the foot.

[0029] Clause 3. The solar panel module mounting system of either of clauses 1 or 2, wherein the at least one first mounting lip is configured to engage with the first side flange, and wherein the at least one second mounting lip is configured to engage with the second side flange.

[0030] Clause 4. The solar panel module mounting system of any of clauses 1-3, wherein the at least one first mounting lip comprises a first pair of mounting lips and wherein the at least one second mounting lip comprises a second pair of mounting lips.

[0031] Clause 5. The solar panel module mounting system of any of clauses 1-4, wherein the at least one attachment tab comprises two attachment tabs, and wherein the at least one protrusion comprises two protrusions, a first protrusion arranged between the first pair of mounting lips and a second protrusion arranged between the second pair of mounting lips.

[0032] Clause 6. The solar panel module mounting system of any of clauses 1-5, wherein the foot assembly further comprises a fastener, and wherein the longitudinal rail defines a rail aperture to receive the fastener therethrough when the rail is supported on the foot assembly.

[0033] Clause 7. The solar panel module mounting system of any of clauses 1-6, wherein the base defines a base aperture configured to receive the fastener therethrough when the base is secured to the foot assembly.

[0034] Clause 8. The solar panel module mounting system of any of clauses 1-7 further comprising a clip arranged within the base, the clip comprising: a through hole configured to receive the fastener therethrough; a first elongated aperture arranged on a first side of the through hole; and a second elongated aperture arranged on a second side of the through hole, opposite the first side.

[0035] Clause 9. The solar panel module mounting system of any of clauses 1-8, wherein the first elongated aperture and the second elongated aperture are configured to receive a56959312.DOCXAttorney Docket No. 10089-2505754 portion of the at least one attachment mechanism therein, when the at least one attachment mechanism is connected to the base.

[0036] Clause 10. The solar panel module mounting system of any of clauses 1-9, wherein the through hole has a first portion and a second portion, the first portion having a larger diameter than a width of the second portion and the second portion being elongated.

[0037] Clause 11. The solar panel module mounting system of any of clauses 1-10, wherein the portion of the at least one attachment mechanism is configured to move the clip such that the fastener transitions from a first portion of the through hole to a second portion of the through hole when the attachment mechanism is transitioned from a first portion to a second position in relation to the rail.

[0038] Clause 12. The solar panel module mounting system of any of clauses 1-11, wherein the second portion of the through hole is flanked by elevated areas.

[0039] Clause 13. The solar panel mounting system of any of clauses 1-12, wherein the base comprises a pair of corresponding apertures configured to align with corresponding features of the at least one attachment mechanism.

[0040] Clause 14. The solar panel mounting system of any of clauses 1-13, wherein the at least one attachment mechanism is one of a low side attachment mechanism and a high side attachment mechanism.

[0041] Clause 15. A solar panel module mounting system comprising: a plurality of foot assemblies for securing at least one rail to a mounting surface, the plurality of foot assemblies each comprise a foot defining a top face and a bottom face, at least a portion of the bottom faces being configured to contact the mounting surface; at least one rail configured to be supported on the plurality of foot assemblies, the at least one rail comprising: an elongated body; a first side flange extending from a first side of the elongated body; and a second side flange extending from a second side of the elongated body, opposite the first side; a plurality of bases comprising: a first base secured to a first end of the longitudinal rail; and a second base secured to a second end of the longitudinal rail; a low side attachment mechanism secured to the first base and configured to rotatably mount a first end of the solar panel module; a high side attachment mechanism secured to the second base and defining a slot configured to receive a second end of the solar panel module therein; wherein at least a portion of the top face defines a support surface configured to support an underside of the elongated body of the at least one rail, wherein the foot comprises at least one protrusion, wherein the plurality of bases comprise at least one attachment tab, and wherein the at least one attachment tab is configured to engage with the at least one protrusion when the base is arranged on top of the at least one rail.66959312.DOCXAttorney Docket No. 10089-2505754

[0042] Clause 16. The solar panel module mounting system of clause 15, wherein the plurality of foot assemblies each comprise a fastener, wherein the at least one rail defines a plurality of apertures each configured to receive one of the fasteners of the plurality of foot assemblies therethrough, and wherein the plurality of bases each define a base aperture configured to receive one of the fasteners of the plurality of foot assemblies therethrough.

[0043] Clause 17. The solar panel module mounting system of either of clauses 15 or 16 further comprising a plurality of clips, the plurality of clips comprising: a first clip arranged within the first base; and a second clip arranged within the second base, wherein the plurality of clips each comprise: a through hole configured to receive one of the fasteners of the plurality of foot assemblies therethrough; a first elongated aperture arranged on a first side of the through hole; and a second elongated aperture arranged on a second side of the through hole, opposite the first side.

[0044] Clause 18. The solar panel module mounting system of any of clauses 15-17, wherein the first elongated aperture and the second elongated aperture of the first clip are configured to receive a portion of the low side attachment mechanism therein, and wherein the portion of the low side attachment mechanism is configured to move the first clip such that the fastener received within the through hole, transitions from a first portion of the through hole to a second portion of the through hole.

[0045] Clause 19. The solar panel module mounting system of any of clauses 15-18, wherein the first elongated aperture and the second elongated aperture of the second clip are configured to receive a portion of the high side attachment mechanism therein, and wherein the portion of the high side attachment mechanism is configured to move the second clip such that the fastener received within the through hole, transitions from a first portion of the through hole to a second portion of the through hole.

[0046] Clause 20. The solar panel module mounting system of any of clauses 15-19, wherein each one of the plurality of bases comprises a pair of corresponding apertures.

[0047] Clause 21. The solar panel module mounting system of any of clauses 15-20, wherein the pair of corresponding apertures of the first base are configured to align with a pair of corresponding apertures of the low side connection mechanism, and wherein the low side attachment mechanism is configured to rotate about an axis defined by the corresponding apertures of the first base.

[0048] Clause 22. The solar panel mounting system of any of clauses 15-21, wherein the pair of corresponding apertures of the second base are configured to receive portions of the76959312.DOCXAttorney Docket No. 10089-2505754 high side attachment mechanism therein, such that the high side mechanism is configured to rotate about the pair of corresponding apertures of the second base.BRIEF DESCRIPTION OF THE DRAWING(S)

[0049] Fig. 1 is a perspective view of a solar panel module mounting system according to one embodiment or aspect of the present disclosure;

[0050] Fig. 2 is a perspective view of a foot of the system of Fig. 1;

[0051] Fig. 3 is a top view of the foot of Fig. 2;

[0052] Fig. 4 is a bottom view of the foot of Fig. 2;

[0053] Fig. 5 is a perspective view of a foot according to another embodiment or aspect of the present disclosure;

[0054] Fig. 6 is a perspective view of an end cap of the system of Fig. 1;

[0055] Fig. 7 is a perspective view of a rail of the system of Fig. 1;

[0056] Fig. 8 is an end view of the rail of Fig. 7;

[0057] Fig. 9 is a perspective view of a first end of the rail of Fig. 7;

[0058] Fig. 10 is a perspective view of a second end of the rail of Fig. 7;

[0059] Fig. 11 is a perspective view of the rail of Fig. 7 mounted on the foot of Fig. 2;

[0060] Fig. 12 is an end view of the rail of Fig. 7 mounted on the foot of Fig. 2;

[0061] Fig. 13 is a top view of the first end of the rail of Fig. 9 mounted on the foot of Fig. 2;

[0062] Fig. 14 is an end view of two rails of Fig. 2 overlapping;

[0063] Fig. 15 is a perspective view of two rails of Fig. 7 overlapping on the foot of Fig. 2;

[0064] Fig. 16 is a first end view of the overlapping rails of Fig. 15;

[0065] Fig. 17 is a second end view of the overlapping rails of Fig. 15;

[0066] Fig. 18 is a perspective view of a ballast rail support clip used in the system of Fig 1;

[0067] Fig. 19 is a perspective view of the ballast rail support clip of Fig. 18 inserted into a rail of Fig. 7;

[0068] Fig. 20 is a perspective view of a ballast rail mounted to the ballast rail support clip;

[0069] Fig. 21 is a perspective view of a ballast block mounted to adjacent ballast rails of the system of Fig. 1;

[0070] Fig. 22A is a perspective view of the system of Fig. 1 with a first ballast block arrangement;

[0071] Fig. 22B is a perspective view of the system of Fig. 1 with a second ballast block arrangement;86959312.DOCXAttorney Docket No. 10089-2505754

[0072] Fig. 23 is a perspective view of a low side attachment mechanism within the system of Fig. 1 with a transparent solar panel module;

[0073] Fig. 24 is a perspective view of the low side attachment mechanism of Fig. 23;

[0074] Fig. 25 is an exploded view of the low side attachment mechanism of Fig. 23;

[0075] Fig. 26 is a perspective view of a bracket of the low side attachment mechanism ofFig. 23;

[0076] Fig. 27 is a perspective view of a seat of the low side attachment mechanism of Fig. 23;

[0077] Fig. 28 is another perspective view of the seat of Fig. 27;

[0078] Fig. 29 is a perspective view of a claw of the low side attachment mechanism of Fig.23;

[0079] Fig. 30A is an end view showing the process of mounting a solar panel module to the low side attachment mechanism of Fig. 23;

[0080] Fig. 30B1 is side view showing the process of mounting a solar panel module to the low side attachment mechanism of Fig. 23;

[0081] Fig. 30B2 is a perspective view of Fig. 30B1;

[0082] Fig. 30C is a side view showing the process of mounting a solar panel module to the low side attachment mechanism of Fig. 23;

[0083] Fig. 30D is a side view showing a solar panel module mounted to the low side attachment mechanism of Fig. 23;

[0084] Fig. 31 is a perspective view of a high side attachment mechanism of the system of Fig. 1;

[0085] Fig. 32 is a perspective view of a lower portion of a pedestal of the high side attachment mechanism of Fig. 31;

[0086] Fig. 33 is a perspective view of an upper portion of the high side attachment mechanism of Fig. 31;

[0087] Fig. 34 is an exploded view of the upper portion of the high side attachment mechanism of Fig. 33;

[0088] Fig. 35 is a perspective view of a mounting section of the pedestal of the high side attachment mechanism of Fig. 31;

[0089] Fig. 36 is a perspective view of an attachment piece of the high side attachment mechanism of Fig. 31;

[0090] Fig. 37A is a side view showing the process of mounting a solar panel module to the high side attachment mechanism of Fig. 31;96959312.DOCXAttorney Docket No. 10089-2505754

[0091] Fig. 37B is a side view showing the process of mounting a solar panel module to the high side attachment mechanism of Fig. 31;

[0092] Fig. 37C is a side view showing the solar panel module mounted to the high side attachment mechanism of Fig. 31;

[0093] Fig. 38 is a perspective view of a wind deflector system connected to the high side attachment mechanism of Fig. 31;

[0094] Fig. 39 is a side view of the wind deflector system connected to the high side attachment mechanism of Fig. 38 (Y-rail not shown);

[0095] Fig. 40 is a perspective view of a top wind deflector of the wind deflector system of Fig. 38;

[0096] Fig. 41 is a perspective view of a bottom wind deflector of the wind deflector system of Fig. 38;

[0097] Fig. 42 is a perspective view of an extra-large wind deflector system;

[0098] Fig. 43. is a perspective view of the extra-large wind deflector system of Fig. 42;

[0099] Fig. 44 is a perspective view of a support of the extra-large wind deflector of Fig. 42;

[0100] Fig. 45 is an exploded view of the support of Fig. 44;

[0101] Fig. 46 is a perspective view of the extra-large wind deflector system of Fig. 42 with only the bottom wind deflector secured;

[0102] Fig. 47 is a perspective view of the extra-large wind deflector system of Fig. 42 with only the middle wind deflector secured;

[0103] Fig. 48 is a perspective view of the extra-large wind deflector system of Fig. 42 with only the top wind deflector secured;

[0104] Fig. 49 is a perspective view of a snow-load assembly of the system of Fig. 1;

[0105] Fig. 50 is an exploded view of the snow-load assembly of Fig. 49;

[0106] Fig. 51 is a perspective view of the load bar of the snow-load assembly of Fig. 49;

[0107] Fig. 52 is a perspective view of a solar panel module mounting system according to another embodiment or aspect of the present disclosure;

[0108] Fig. 53 is a perspective view of a foot of the system of Fig. 52;

[0109] Fig. 54 is a top view of the foot of Fig. 53;

[0110] Fig. 55 is a bottom view of the foot of Fig. 53;

[0111] Fig. 56 is a perspective view of a support rail of the system of Fig. 52 mounted to the foot of Fig. 53;

[0112] Fig. 57 is an end view of the support rail of Fig. 56 mounted to a foot of Fig. 53;

[0113] Fig. 58 is a perspective view of a mounting rail of the system of Fig. 52;106959312.DOCXAttorney Docket No. 10089-2505754

[0114] Fig. 59 is cross-sectional view of the mounting rail of Fig. 58 taken at line 59-59;

[0115] Fig. 60 is an end view of the mounting rail of Fig. 58 overlapping the support rail of Fig. 56;

[0116] Fig. 61 is a front perspective view of a ballast rail support clip of the system of Fig. 52;

[0117] Fig. 62 is a rear perspective view of the ballast rail support clip of Fig. 61;

[0118] Fig. 63 is a perspective view of the ballast support clip of Fig. 61 on a mounting rail of Fig. 58;

[0119] Fig. 64 is an end view of the ballast support clip of Fig. 61 on a mounting rail of Fig. 58;

[0120] Fig. 65 is a perspective view of a ballast rail of the system of Fig. 52;

[0121] Fig. 66 is a perspective view of a ballast rail of Fig. 65 on a ballast rail support clip of Fig. 61;

[0122] Fig. 67 is a side view of a ballast rail mounted on a ballast rail support clip;

[0123] Fig. 68 is a side view of two ballast rails mounted on a ballast rail support clip;

[0124] Fig. 69 is a perspective view of a ballast system of the system of Fig. 52;

[0125] Fig. 70 is a side view of a ballast system of Fig. 69;

[0126] Fig. 71 is a perspective view of a low side attachment mechanism of the system of Fig. 52;

[0127] Fig. 72 is an exploded view of the low side attachment mechanism of Fig. 71;

[0128] Fig. 73 is a front perspective view of a bracket of the low side attachment mechanism of Fig. 71;

[0129] Fig. 74 is a rear perspective view of the bracket of Fig. 73;

[0130] Fig. 75 is a front perspective view of a seat of the low side attachment mechanism of Fig. 71;

[0131] Fig. 76 is a rear perspective view of the seat of Fig. 75;

[0132] Fig. 77A is a front perspective view of a claw of the low side attachment mechanism of Fig. 71;

[0133] Fig. 77B is a rear perspective view of the claw of Fig. 77;

[0134] Fig. 78 is a rear view of the claw of Fig. 77;

[0135] Fig. 79A is a side view showing the process of mounting a solar panel module to the low side attachment mechanism of Fig. 71;

[0136] Fig. 79B1 is a side view showing the process of mounting a solar panel module to the low side attachment mechanism of Fig. 71;116959312.DOCXAttorney Docket No. 10089-2505754

[0137] Fig. 79B2 is a rear perspective view of Fig. 79B1;

[0138] Fig. 79B3 is a rear view of Fig. 79B1;

[0139] Fig. 79C is a side view showing a solar panel module mounted to the low side attachment mechanism of Fig. 71;

[0140] Fig. 80 is a perspective view of a high side attachment mechanism of the system of Fig. 52;

[0141] Fig. 81 is a lower perspective view of a tilt arm of the high side attachment mechanism of Fig. 80;

[0142] Fig. 82 is a side view of a solar panel module mounted to the high side attachment mechanism of Fig. 80;

[0143] Fig. 83 is a perspective view of overlapping mounting and support rails of the system of Fig. 52;

[0144] Fig. 84 is another perspective view of overlapping mounting and support rails of the system of Fig. 52;

[0145] Fig. 85 is a perspective view of a solar panel array;

[0146] Fig. 86 is a perspective view of adjacent mounting mechanisms and rails in the circle labeled 86 in Fig. 85;

[0147] Fig. 87 is a perspective view of adjacent mounting mechanisms and rails in the circle labeled 87 in Fig. 85;

[0148] Fig. 88 is a perspective view of adjacent mounting mechanisms and rails in the circle labeled 88 in Fig. 85;

[0149] Fig. 89 is a perspective view of a rail assembly having a mounting rail, low side attachment mechanism, and high side attachment mechanism of the system of Fig. 52 in a storage position;

[0150] Fig. 90A shows a first end view of two stacked rail assemblies of Fig. 89;

[0151] Fig. 90B shows a second end view of two stacked rail assemblies of Fig. 89;

[0152] Fig. 91A shows a perspective view of a solar panel module mounting system with a single solar panel mounted according to another embodiment or aspect of the present disclosure;

[0153] FIG. 9 IB shows a front perspective view of a solar panel module array mounted to the solar panel module mounting system of Fig. 91 A;

[0154] FIG. 91C shows a rear perspective view of a solar panel module array mounted to the solar panel module mounting system of Fig. 91 A;126959312.DOCXAttorney Docket No. 10089-2505754

[0155] FIG. 92A shows a perspective view of a foot assembly of the solar panel module mounting system of Fig. 91 A;

[0156] FIG. 92B shows an exploded view of the foot assembly of FIG. 92 A;

[0157] FIG. 93 A shows a perspective view of the foot of the foot assembly of Fig. 92A;

[0158] FIG. 93B shows a top view of the foot of FIG. 93 A;

[0159] FIG. 93C shows a bottom perspective view of the foot of FIG. 93 A;

[0160] FIG. 93D shows a first side view of the foot of FIG. 93 A;

[0161] FIG. 93E shows a second side view of the foot of FIG. 93 A;

[0162] FIG. 94 shows a perspective view of the cover of the foot assembly of Fig. 92 A;

[0163] FIG. 95 A shows a perspective view of a rail of the mounting system of FIG. 91 A;

[0164] FIG. 95B shows a top view of a first end of the rail of FIG. 95 A;

[0165] FIG. 95C shows a top view of a second end of the rail of FIG. 95 A;

[0166] FIG. 96A shows a side view of the rail of FIG. 95 A attached to the foot assembly of FIG. 92 A;

[0167] FIG. 96B shows a perspective view of the first end of the rail of FIG. 95 A attached to the foot assembly of FIG. 92A with the fastener omitted;

[0168] FIG. 97A shows a top perspective view of a ballast support rail clip of the mounting system of FIG. 91 A;

[0169] FIG. 97B shows a rear perspective view of the ballast support rail clip of FIG. 97 A;

[0170] FIG. 98 shows a perspective view of a base of the mounting system of FIG. 91 A;

[0171] FIG. 99 shows a perspective view of a ballast system of the mounting system of FIG. 91 A;

[0172] FIG. 100 A shows a perspective view showing the process of installing a ballast system;

[0173] FIG. 100B shows a perspective view showing the process of installing a ballast system;

[0174] FIG.100C shows a perspective view showing the process of installing a ballast system;

[0175] FIG. 100D shows a perspective view showing the process of installing a ballast system;

[0176] FIG. 101 shows a perspective view of a clip of the mounting system of FIG. 91 A;

[0177] FIG. 102A shows a perspective view of a high side attachment mechanism of the mounting system of FIG. 91 A;136959312.DOCXAttorney Docket No. 10089-2505754

[0178] FIG. 102B shows an exploded view of a high side attachment mechanism of the mounting system of FIG. 91 A;

[0179] FIG. 103 shows a perspective view of a tilt arm of the high side attachment mechanism of FIG. 102 A;

[0180] FIG. 104 shows a perspective view of a locking piece of the high side attachment mechanism of FIG. 102 A;

[0181] FIG. 105 shows an exploded view of the foot assembly of FIG. 93A and base of the high side attachment mechanism of FIG. 102A;

[0182] FIG. 106 shows a perspective view of a seat of a low side attachment mechanism of the mounting system of FIG. 91 A;

[0183] FIG. 107A shows a front perspective view of a low side attachment mechanism attached to a rail of FIG. 95 A;

[0184] FIG. 107B shows a rear perspective view of a low side attachment mechanism attached to a rail of FIG. 95 A;

[0185] FIG. 108 shows a perspective view of a bracket of the wind deflector assembly of the mounting system of FIG. 91 A; and

[0186] FIG. 109 shows a perspective view of a wind deflector of the wind deflector assembly of the mounting system of FIG. 91 A.DESCRIPTION OF THE INVENTION

[0187] As used herein, the singular form of “a”, “an”, and “the” include plural referents unless the context clearly dictates otherwise.

[0188] Spatial or directional terms, such as “left”, “right”, “inner”, “outer”, “above”, “below”, “horizontal”, “vertical” and the like, relate to the disclosure as shown in the drawing figures and are not to be considered as limiting as the disclosure can assume various alternative orientations.

[0189] The terms “first”, “second”, and the like are not intended to refer to any particular order or chronology, but refer to different conditions, properties, or elements.

[0190] The term “includes” is synonymous with “comprises”.

[0191] As used herein, the terms “parallel” or “substantially parallel” mean a relative angle as between two objects (if extended to theoretical intersection), such as elongated objects and including reference lines, that is from 0° to 5°, or from 0° to 3°, or from 0° to 2°, or from 0° to 1°, or from 0° to 0.5°, or from 0° to 0.25°, or from 0° to 0.1°, inclusive of the recited values.146959312.DOCXAttorney Docket No. 10089-2505754

[0192] As used herein, the terms “perpendicular” or “substantially perpendicular” mean a relative angle as between two objects at their real or theoretical intersection is from 85° to 90°, or from 87° to 90°, or from 88° to 90°, or from 89° to 90°, or from 89.5° to 90°, or from 89.75° to 90°, or from 89.9° to 90°, inclusive of the recited values.

[0193] Introduction

[0194] Please note that not all features will be labeled with their element number each time that feature appears in the drawings. Each feature is labeled at least once, and their placement should be clear given the description and the labeling in other figures. Additionally, fasteners are frequently described as being used to connect and / or secure one or more features together. These fasteners are not always shown in the drawings. Based on the description, one will understand how the fasteners are used to connect and / or secure the different features together. Examples of fasteners may be a bolt, rivet, or a screw. Other fasteners that are known in the art may be used, so long as the functionality of the features used with the fastener are not impeded.

[0195] Present disclosure is directed to systems 10, 300, 500, for securing solar panel modules P and ballast blocks to a roof or another surface. The first system 10 and its components are shown in Figs. 1-51. The second system 300 and its components are shown in Figs. 52-90. The third system 500 and its components are shown in Figs. 91A-109. In all systems, 10, 300, 500, a solar panel module P is shown.

[0196] The solar panel module P is representative of those that can be used with the system 10, 300, 500. As shown, the solar panel modules P are intended to represent a photovoltaic panel connected to a frame, with the frame arranged to be secured to different attachments and / or mounting mechanisms to secure the solar panel module P on a surface, either individually or with others within an array. In some figures, the photovoltaic panel is either transparent or not shown. However, one will understand how the photovoltaic panel is arranged based on the context of the figures and the description provided herein. One having skill in the art will appreciate that the systems 10, 300, 500, disclosed in this application can be used with this kind of solar panel module P as well as others. In most instances, the relevant components of the systems 10, 300, 500, engage with and / or support the frame of the solar panel module P, as opposed to the photovoltaic panel. However, the systems 10, 300, 500, are capable of being engaged with other parts of the solar panel module P or other features connected to the frames.

[0197] The term solar panel module P represents the combination of a photovoltaic panel and frame as well as any other different systems, features, or components that can be involved156959312.DOCXAttorney Docket No. 10089-2505754 in securing a photovoltaic panel to a surface. Terms like solar panel, module, frame, module frame, etc. may be used interchangeably with solar panel module P. Depending on how the features of a specific solar panel module are arranged, modifications to the systems 10, 300, 500, and their relevant components may be made to accommodate that specific solar panel module P. These modifications are contemplated by this disclosure. Such modifications may become apparent when the present disclosure is viewed in light of a specific solar panel module arrangement.

[0198] System 10

[0199] In Figs. 1-51, a first solar panel module system 10 and its components are shown. Examples of these components working together to support a single solar panel module P is shown in Fig. 1, but the system can be used to support multiple solar panel modules P within an array. The specifics of the system 10 and its components are discussed in greater detail below.

[0200] With reference to Fig. 1, the system includes feet 12 that are used to support the system 10 on a roof (not shown) or another support surface. The arrangement of the system 10 allows for less contact points with the roof than other systems known in the art. Rails 60 are secured to the feet 12, and the rails 60 can support ballast blocks 114 or provide mounting points for a low side attachment mechanism 120 and / or a high side attachment mechanism 170, which are used to secure the solar panel module P. The rails 60 are identical and can be used for either function. The rails 60 used to mount the low side attachment mechanism 120 and the high side attachment mechanism 170 are called Y-rails and are thought of as extending in a north-south direction in a south facing array. When referring to these rails 60 specifically, they will be referred to as Y-rails 60A. The rails 60 used to support the ballast blocks are called X-rails and are thought of as extending in an east-west direction in a south facing array. When referring to these rails specifically, they will be referred to as X-rails 60B.

[0201] Foot / Pad

[0202] With reference to Figs. 2-4, an example of a foot 12 used in system 10 is shown. The foot 12 includes a body 14, defining a top face 16 and a bottom face 18. The top face 16 is used to support the rails 60, and the bottom face 18 is used to contact the roof. At the bottom of the body 14, proximate the bottom face 18, drainage holes 20 can be formed to allow water to flow out of the foot 12. Extending from the body 14, at or proximate to the corners of the foot 12, are mounting posts 22A, 22B, 22C, 22D. The mounting posts 22A, 22B, 22C, 22D are used to secure either a Y-rail 60 A or an X-rail 60B to the foot 12. Extending respectively from a midportion of the mounting posts 22A, 22B, 22C, 22D are first mounting lips 24A, 24B,166959312.DOCXAttorney Docket No. 10089-250575424C, 25D. The first mounting lips 24A, 24B, 24C, 24D are used to secure a flange 68, 70 of the Y-rail 60A against the foot 12. Extending respectively from a top portion or a top surface of the mounting posts 22A, 22B, 22C, 22D are second mounting lips 25A, 25B, 25C, 25D. The second mounting lips 25A, 25B, 25C, 25D can be used to secure either the Y-rail 60A or the X-rail 60B to the foot 12. How each of these features are used to secure the rails 60A, 60B to the foot 12 will be discussed in greater detail below.

[0203] Parts of the top face 16 of the foot 12 are used to support an underside of either the Y-rail 60 A or the X-rail 60B. Specifically, the top face 16 defines a first rail support surface 26, a second rail support surface 28, a third rail support surface 30, and a fourth rail support surface 32. The first rail support surface 26 may be substantially symmetrical to the second rail support surface 28, and the third rail support surface 30 may be substantially symmetrical to the fourth rail support surface 32. All of the support surfaces 26, 28, 30, 32 are arranged to support a Y-rail 60A, while only parts of all of support surfaces 26, 28, 30, 32 are arranged to support an X-rail 60B. The top face 14 also has alignment ridges 46A, 46B proximate a midpoint of the foot 12. The alignment ridges 46A, 46B extend from opposing sidewalls 47A, 47B that extend between opposing mounting posts 22A, 22D and 22B, 22C. As shown, alignment ridge 46A is disposed between mounting posts 22A, 22D, and alignment ridge 46B is disposed between mounting posts 22B, 22C. The alignment ridges 46A, 46B can be used for visual or physical alignment with corresponding features on the Y-rail 60A to ensure proper positioning of the Y-rail 60A within the foot 12. This can help ensure that the Y-rails 60A used within the system 10 and a larger solar panel array are properly arranged to permit the mounting of multiple solar panel modules P of various widths.

[0204] The first rail support surface 26 extends between the first mounting post 22A and the second mounting post 22B, and includes a first flange support surface 34A, a second flange support surface 34B, a first body support surface 36, a first sloped surface 37A, and a second sloped surface 37B. The flange support surfaces 34A, 34B flank the first body support surface 36 and are disposed lower than the first body support surface 36. The sloped surfaces 37A, 37B respectively connect the flange support surfaces 34A, 34B to the first body support surface 36. The second rail support surface 28 extends between the third mounting post 22C and the fourth mounting post 22D and includes a third flange support surface 38 A, a fourth flange support surface 38B, a second body support surface 40, a third sloped surface 41 A, and a fourth sloped surface 41B. The flange support surfaces 38A, 38B flank the second body support surface 40 and are disposed lower than the second body support surface 40. The sloped surfaces 41A, 41B respectively connect the flange support surfaces 38A, 38B to the second176959312.DOCXAttorney Docket No. 10089-2505754 body support surface 40. The shape of the first and second rail support surfaces 26, 28 is such that the Y-rail 60 A can fit over the first and second rail support surfaces 26, 28 and rest thereon. This is shown in Figs. 11, 12, and 15-17.

[0205] The third rail support surface 30 extends from a midpoint of the first rail support surface 26, and the fourth rail support surface 32 extends from a midpoint of the second rail support surface 28. As shown, the third rail support surface 30 extends from the body support surface 36 of the first rail support surface 26, and the fourth rail support surface 32 extends from the body support surface 30 of the second rail support surface 28. The third rail support surface 30 and the fourth rail support surface 32 extend toward each other and meet at an aperture surface 33 located proximate to the center of the foot 12. The aperture surface 33 includes an aperture 44 that extends into the body 14 in the direction of the bottom surface 18, which will be discussed below. Although not shown, a threaded nut may be provided in the aperture 44 to facilitate the engagement with a fastener to secure different features to the foot 12. As shown, the third and fourth support surfaces 30, 32 extend like ridges across the body 14 until they connect to the aperture surface 33. As will soon be apparent, in some embodiments, the aperture surface 33 and aperture 44 may be left out of the foot 12. In this instance the third support surface 30 and fourth support surface 32 may simply be one support surface extending between the first support surface 26 and the second support surface 28. The third rail support surface 30 and the fourth rail support surface 32 are arranged to further support the elongated body 62 of the Y-rail 60A when it is secured within the foot 12. The aperture surface 33 can also act as a Y rail support surface and is flanked by two sloped surfaces and two flange support surfaces similar to the first rail support surface 26 and the second rail support surface 28.

[0206] Fig. 5 shows a second embodiment of a foot 12’. Similar features use the same reference numbers as those used with the foot 12 in Figs. 2-4. This foot 12’ allows for multiple positionings of X-rails 60B’ to be used on the foot 12’. Relative to the first embodiment of Figs. 2-4, the foot 12’ includes secondary mounting posts 50A’, 50B’, 50C’, 50D’ having secondary mounting lips 51 A’, 5 IB’, 51C’, 5 ID’. Respectively, the secondary mounting posts 50A’, 50B’, 50C’, 50D’ are arranged across from the mounting posts 22A’, 22B’, 22C’, 22D’. This allows for two X-rails 60B’ to be connected to the foot 12’. In this arrangement, the second flange 70’ of the first X-rail 60B’ contacts the first and second secondary mounting posts 50A’, 50B’ and is supported by the third support surface 30’, and the first flange 68’ of a second X-rail 60B’ contacts the third and fourth secondary mounting posts 50C’, 50D’ and is supported by the fourth support surface 32’.186959312.DOCXAttorney Docket No. 10089-2505754

[0207] The foot 12’ allows for the same central mounting position as the foot 12 and additionally allows for two alternate X-rail 60B’ mounting positions when an X-rail 60B’ is mounted to the foot 12 on top of a Y-rail 60 A.

[0208] Fig. 6 shows an end cap 52 that is used at the ends 64, 66 of the rails 60. The end cap 52 is made of a softer material than the rail 60 and protects the roof or support surface from any damage that may occur if it were to contact the ends 64, 66 of the rails 60. It also protects wiring related to the solar panel module P from sharp edges. The plugs 52 also protect installers or other people on the roof or support surface from being injured by the potentially sharp ends 64, 66 of the rails 60. The end cap 52 includes a body 54 having a base 56 and slots 58 defined above the base 56. The slots 58 are shaped like the end profile of the rail 60 and are sized to fit one or two rails 60 therein.

[0209] Rails

[0210] With reference to Figs. 7-10, a rail 60 that may be interchangeably used as a Y-rail 60 or an X-rail 60’ is shown. The rail 60 includes an elongated body 62 extending between a first end 64 and a second end 66. A first side flange 68 and a second side flange 70 extend from opposing sides of the elongated body 62. Although not all are numbered, alignment slots 72A, 72B are formed along the same points of the side flanges 68, 70. Alignment slots 72A, 72B receive the alignment ridges 46A, 46B of the foot 12 when corresponding apertures 82, 84, 86A, 86B, 86C are aligned with aperture 44 and or threaded nut 45 and the parts of the rail 60 having the alignment slots 72A, 72B are secured to the foot 12. When the rail 60 is used as a Y-rail 60, the rail 60 can be divided into different segments, each having different features to facilitate connections with different features described throughout this disclosure. These segments are a low side segment 74, a high side segment 76, and an overlapping segment 78.

[0211] The low side segment 74 is located proximate the first end 64 and includes notches 80 and or other indicators located along the side flanges 68, 70. The notches 80 are formed with indentations in the side flanges 68, 70. The notches 80 are arranged to provide a visible indicator next to the alignment ridges 46A, 46B of the foot 12. This allows for the low side segment 74 to be placed at a specific location within the foot 12 to facilitate the consistent alignment of rails 60 within a solar panel array. In some embodiments, the alignment ridges 46A, 46B can be received within the notches 80 acting as a physical keyway to locate the alignment ridges 46A, 46B in the appropriate notches 80 for any particularly sized solar module P. Adjacent to the notches 80 are distance markers, which are examples of an indicator that can also be used. The distance markers also help an installer to align the low side segment 74 at a specific position within the foot 12 for the specific solar panel module P width. This adjusts196959312.DOCXAttorney Docket No. 10089-2505754 the system configuration for specific module widths while maintaining the nominal slope of the modules P within the system 10. In Fig. 13, a low side segment 74 is placed within the foot 12, with the alignment ridges 46A, 46B aligned within opposing notches 80. The elongated body 62 also defines a slot 82 along the low side segment 74. The slot 82 is used to secure a low side attachment mechanism 120 to the rail 60. Specifically, a mounting aperture 132 formed in a bracket 122 of the low side attachment mechanism 170 is arranged to be aligned along the slot 82. The specific features of the low side attachment mechanism 170 are discussed in greater detail below. The slot 82 is also arranged to align with an overlapping hole 86A, 86B, 86C formed in a second rail 60 to secure the second rail 60 to the first 60. Finally, the slot 82 is configured to be aligned with the aperture 44 and threaded nut 45 formed in the foot 12. A single fastener is received through the mounting aperture 132, one of the overlapping holes 86A, 86B, 86C, the slot 82, the aperture 44 and the threaded nut 45 to secure all of these features to one another.

[0212] The high side segment 76 is located a distance away from the low side segment 74, closer to the second end 66 of the rail 60. Along the high side segment 76, the elongated body 72 defines a first mounting hole 84 that is arranged to align with an aperture 210 formed in a pedestal 172 of the high side attachment mechanism 170. The first mounting hole 84 and aperture 210 receive a fastener 212 to secure the pedestal 172 to the high side segment 76 of the rail 60. The high side segment 76 also includes a toe hole 92 that may be arranged to receive a toe 211 that is also formed in the pedestal of the high side attachment mechanism 170. These connections will be discussed in more detail with the high side attachment mechanism 170.

[0213] The overlapping segment 78 is arranged between the high side segment 76 and the second end 66 of the rail 60. The overlapping segment includes three overlapping holes 86A, 86B, 86C defined within the top of the elongated body 62. The overlapping segment 78 is arranged to overlap with a low side segment 72 of an adjacent rail 60 in the Y-direction. Specifically, one of the overlapping holes 86A, 86B, 86C will be aligned with the slot 82 of the low side segment of the adjacent rail 60 and the aperture 44 of the foot 12, 12’. As noted above, the overlapping holes 86A, 86B, 86C will also be aligned with a mounting aperture 132 of the low side attachment mechanism 170. The desired space between the high side attachment and the low side attachment is affected by the shading of the modules P in one row up on the module P in the adjacent row to the north among other factors and this results in the desired row spacing. Overlapping hole 86A, 86B, 86C allow for various row spacings and will be aligned with the low side segment 72 of the adjacent rail 60.206959312.DOCXAttorney Docket No. 10089-2505754

[0214] Disposed at various points along the length of the rail 60, adjacent to and between the different segments 74, 76, 78, are high load holes 88 and ballast rail support clip slots 90. The high load holes 88 are arranged to align with corresponding apertures 262, 264 formed in the bases 258, 260 of a high load assembly 250. The holes 88 and apertures 262, 264 receive fasteners to secure the high load assembly 250 to the rail. The ballast support clip slots 90 are designed to receive a portion of a ballast support clip 100 therein. The ballast support clip 100 is designed to secure an X-rail 60B to the Y-rail 60A. In this instance the X-rails 60B act as ballast rails. The ballast support clip slots 90 are spaced to allow two X-rails 60B to be secured to a single Y-rail 60A thereby forming a space between the adjacent X-rails 60B that can receive a ballast block 114. The adjacent X-rails 60B are spaced to both support the ballast block 114. This will be discussed in greater detail below.

[0215] Viewing the rail 60 as a whole, each of the different apertures 82, 84, 86A, 86B, 86C, 88, 90, 92 are arranged along each rail 60 to facilitate easy assembly of overlapping rails 60 and the other features that are connected to the rails 60. Specifically, the apertures 82, 84, 86A, 86B, 86C, 88, 90, 92 are spaced apart so that once a specific part of a first Y-rail 60A is secured to a first foot 12, the other rails 60 A, 60B and components that connect to the rails 60A, 60B will automatically be aligned and correctly oriented relative to one another, so long as the other Y-rail s 60 A are secured to their feet 12 in the same manner as the first Y-rail 60 A. One way this can easily be accomplished is by lining up the same alignment slots 72A, 72B formed in the high side segment 76 and / or the overlapping segment 78 with the alignment notches 46A, 46B of the feet 12. Another way to accomplish this is to use the notches 80 in the low side segment 74 and aligning the same individual notch 80 with the alignment ridges 46 A, 46B.

[0216] The shape of the rails 60 allows them to overlap one another in the same direction. This is shown in Fig. 14 where the elongated body 62 and side flanges 68, 70 of a bottom rail 60 are below and in contact with the elongated body 62’ and side flanges 68’, 70’ of a top rail 60’. In this instance the top rail 60’ is another Y-rail 60A.

[0217] With reference to Figs. 2-4, 11, 12, and 15-17, the process of mounting the Y-rail 60A to the foot 12 will now be described. The rail support surfaces 26, 28, 30, 32 and the Y- rail 60 A are arranged so that a first flange 68 of the Y-rail 60 A rests on the first flange support surfaces 34A, 38A, a second flange 70 of the Y-rail 60A rests on the second flange support surfaces 34B, 38B, and the body 62 of the Y-rail 60A rests on the body support surfaces 36, 40, the third rail support surface 30, and the fourth rail support surface 32. Sidewalls of the elongated body 62 may also rest on the sloped surfaces 37A, 37B, 41A, 41B. The mounting216959312.DOCXAttorney Docket No. 10089-2505754 posts 22 A, 22B, 22C, 22D can be arranged to contact the ends of the flanges 68, 70 of the Y- rail 60A, allowing the Y-rail 60A to be secured in the foot 12 via a snap fit. The Y-rail 60A is flexible to facilitate this connection, and in some instances, the Y-rail 60A may bend or flex as it is being mounted, so that Y-rail 60A snaps or clips into place against the mounting posts 22A, 22B, 22C, 22D, with the Y-rail 60A being supported on top of the support surfaces 26, 28, 30, 32.

[0218] The first mounting lips 24A, 24B, 24C, 24D extend from their respective mounting posts 22A, 22B, 22C, 22D to engage with the flanges 68, 70 of the Y-rail 60A. As shown, mounting lips 24B, 24C are arranged to engage the second flange 68, and mounting lips 24A, 24D are arranged to engage the first flange 70. The mounting lips 24A, 24B, 24C, 24D extend over a respective flange support surfaces 34A, 34B, 38 A, 38B to define respective mounting spaces 42A, 42B, 42C, 42D with the flange support surfaces 34A, 34B, 38 A, 38B. The mounting spaces 42A, 42B, 42C, 42D are sized to accommodate the side flanges 68, 70 of the Y-rail 60A. In some instances, the first mounting lips 24A, 24B, 24C, 24D may contact and / or dig into the side flanges 68, 70 to further facilitate the connection between the Y-rail 60A and the foot 12. In other instances, the first mounting lips 24A, 24B, 24C, 24D may only define the mounting spaces 42A, 42B, 42C, 42D, which essentially serve as receiving slots for the flanges 68, 70, allowing the Y-rail 60A to be secured to the foot 12 via the snap fit. Depending on what segment 74, 76, 78 of the Y-rail 60A is directly secured to the foot, one of the slot 82, first mounting hole 84, or overlapping holes 86A, 86B, 86C may be aligned with the aperture 44 to receive a fastener (not shown) to further secure the Y-rail 60 A to the foot 12.

[0219] Referring to Figs. 2-4, the process of mounting the X-rail 60B to the foot 12 will now be described. As noted above, only parts of the support surfaces 30, 32 are arranged to support the X-rail 60B directly on the foot 12. Specifically, the third rail support surface 30 supports the first flange 68’ of the X-rail 60B, and the fourth rail support surface 32 supports the second flange 70’. Similar to their engagement with the Y-rail 60A, mounting posts 22A, 22B, 22C, 22D are arranged, so that the edges of the flanges 68’, 70’ of the X-rail 60B are secured between the mounting posts 22A, 22B, 22C, 22D via a snap fit. The first flange 68’ fits against mounting posts 22A, 22B, and the second flange 70’ fits against mounting posts 22C, 22D. In other words, the first flange 68’ is frictionally engaged with mounting posts 22A, 22B, the second flange 70’ is frictionally engaged with mounting posts 22C, 22D, and the X- rail 60B spans the distance between each of the mounting posts 22A, 22B, 22C, 22D. The X- rail 60B is flexible to facilitate this connection, and in some instances, the X-rail 60B may bend or flex, so that upon its release, the X-rail 60B snaps or clips into place against the mounting226959312.DOCXAttorney Docket No. 10089-2505754 posts 22A, 22B, 22C, 22D. Second mounting lips 25A, 25B, 25C, 25D are arranged along the mounting posts 22A, 22B, 22C, 22D to help secure the X-rail 60B on the foot 12. The second mounting lips 25A, 25B, 25C, 25D extend from the mounting posts 22A, 22B, 22C, 22D a distance above the third and fourth support surfaces 30, 32. This allows the flanges 68’, 70’ to fit under the second mounting lips 25A, 25B, 25C, 25D to be properly oriented on the foot 12. The second mounting lips 25A, 25B, 25C, 25D also prevent the X-rail 60B from lifting up and away from the foot 12 after it has been secured. The second mounting lips 25A, 25B, 25C, 25D may also be arranged to contact the flanges 68’, 70’ to further secure the X-rail 60B. In another embodiment, the X-rail 60B and the mounting posts 22A, 22B, 22C, 22D may be sized differently to allow the flanges 68’, 70’ to contact parts of the first and second rail support surfaces 26, 28. In this instance, parts of the body support surfaces 36, 40 act as flange support surfaces for the X-rail 60B.

[0220] With reference to Figs. 15-17, both a Y-rail 60A and an X-rail 60B are connected to the foot 12. In this instance, the Y-rail 60A is fit into the foot as described above. The X- rail 60B extends over the Y-rail 60A and the foot 12, so that the second flange 70’ of the X- rail 60B contacts the top surface of the Y-rail 60 A. Two mounting posts 22 A, 22B (not visible in Fig. 15) fits under the elongated body 62’ of the X-rail 60B. As shown in Fig. 16, the second mounting lip 25A may contact part of the elongated body 62’ to help align the X-rail 60B over the Y-rail 60A on the foot 12. This may provide additional support for the X-rail 60B. Although not shown, it is contemplated that the mounting posts 22A, 22B, 22C, 22D and the second mounting lips 25A, 25B, 25C, 25D may be sized and shaped to provide more support to the elongated body of the X-rail 60B. For example, the mounting posts 22 A, 22B, 22C, 22D may extend a greater distance above the foot 12, so that a top surface of the mounting posts 22A, 22B, 22C, 22D contacts the flat underside of the elongated body 62’ . In the arrangements shown, additional features may be needed to secure the X-rail 60B in place. These will be discussed below.

[0221] Ballast Rail Support Clip & Ballast Arrangement

[0222] With reference to Figs. 18-20, a ballast rail support clip 100 is shown. The ballast rail support clip 100 is designed to fit partially inside of the ballast rail support clip slots 90 formed in the Y-rails 60A. An X-rail 60B is then secured to the ballast rail support clip 100 to act as ballast rail. The ballast rail support clip 100 includes a body 102 that has a central portion 104 and elongated portions 106 A, 106B extending from opposing ends of the central portion 104. Rail lips 108 A, 108B respectively extend from the ends of the elongated portions 106A, 106B. The central portion 104 extends below a plane defined by the elongated portions 106 A,236959312.DOCXAttorney Docket No. 10089-2505754106B and terminates with a rounded end 110. Wings 112A, 112B extend from the central portion 104, beginning below the plane of the elongated portions 106 A, 106B, proximate the rounded end 110. The wings 112A, 112B terminate a distance above the plane of the elongated portions 106A, 106B. The wings 112A, 112B respectively define locking flanges 113A, 113B between the ends of the wings 112 A, 112B.

[0223] The rounded end 110 is designed to be received within the ballast rail support clip slots 90 (hereinafter called “slots”) defined within the rails 60. The ballast rail support clip 100 is made of a resilient material, that can be a metal or plastic as two examples. The curve of the rounded end 104 and the angles formed by the locking flanges 113 A, 113B allow the central portion 104 and the wings 112A, 112B to deform to be fit within the slots 90. The locking flanges 113 A, 113B contact the bottom surface of the rail 60, adjacent to the slot 90, to secure the ballast rail support clip 100 therein. To insert the ballast rail support clip 100 within the slot, an installer may press the wings 112A, 112B toward each other to bend the ballast rail support clip 100 to fit it within the slot 90, or an installer may align the rounded end 110 with the slot 90 and press downward, until the body 102 deforms and enters the slot 90. The ballast rail support clip 100 will deform as it enters the slot 90 and then at least partially retake the shape shown in Fig. 18, but with part of the central portion 104 and / or the locking flanges113 A, 113 A pressing against the sidewall of the slot 90.

[0224] The rail lips 108A, 108B engage with the side flanges 68’, 70’ of an X-rail 60B. The X-rail 60B is shaped to fit over the ballast rail support clip 100, so that the side flanges 68’ 70’ engage with the rail lips 108 A, 108B via a frictional fit. One way to support a ballast block114 is inserting two ballast rail support clips 100 into adjacent slots 90 on the Y-rail 60A, and engaging two X-rails 60B with the ballast rail support clips 100. The slots 90 are spaced along the Y-rail 60A, so that the space formed between the second flange 70’ of a first X-rail 60B and the first flange 68’ of a second X-rail 60B can support a ballast block 114 between them. Fig. 21 shows a single ballast block 114 on adjacent X-rails 60B, and Figs. 22A and 22B show a number of ballast blocks 114 supported by adjacent X-rails 60B. Like the Y-rails 60A discussed in connection with Figs, as shown in Figs. 22A and 22B, the X-rails 60B can be spaced at various intervals along the Y-rails 60A to allow for some or all of the ballast bocks to be arranged laterally or longitudinally. The rails 60A, 60B and feet 12 are made of strong enough material to support such arrangements. Another way to support a ballast block 114 is to secure an X-rail 60B to the clamp 214 of the high side attachment mechanism 170, and secure an adjacent X-rail 60B to a ballast rail support clip 90.246959312.DOCXAttorney Docket No. 10089-2505754

[0225] Although the X-rails 60B are described as being used in connection with a ballast rail support clip 90, it is contemplated that ballast rail support clips 90 are not used, and in some embodiments, the X-rails 60B may be integral with the Y-rails 60A.

[0226] Low Side Attachment

[0227] With reference to Figs. 23-29, the low side attachment mechanism 120 and its relevant components will now be described. The low side attachment mechanism 120 includes a bracket 122, a seat 134, a claw 154, and a fastener 168 to secure the bracket 122 to the Y-rail 60 A and the foot 12, 12’ . The seat 134 is mounted to the bracket 122 and is arranged to support the solar panel module P in various mounting positions (shown in Figs. 30A-30D). The claw 154 is arranged to secure the solar panel module P to the seat 134. With these functions in mind, the individual features of each of these elements will now be described.

[0228] Figs. 24-27 show the bracket 122. The bracket 122 has opposing sidewalls 124A, 124B that define a space 125 therebetween. The space 125 is sized to receive the claw 154 and / or parts of the seat 134 and solar panel module P when the solar panel module P is mounted. The opposing sidewalls 124A, 124B each define a bracket aperture 126, which may define a rotation axis R1 for the seat 134, claw 154, and solar panel module P. Above the bracket apertures 126A, 126B, the opposing sidewalls 124A, 124B include top portions 128A, 128B that are designed to be received within the seat 134 and to contact the solar panel module P in the mounted position. This helps to secure the module P and to form an electrical grounding / bonding path. A rail mounting section 130 extends between the opposing sidewalls 128A, 128B. The rail mounting section 130 defines the mounting aperture 132 that is used to receive the fastener 168 that secures the bracket 122 to the Y-rail via the slot 82 in the low side segment 74. The fastener 168 also secures the bracket 122 to the foot 12 by extending through the aperture 44 and or the threaded nut 45. The opposing sidewalls 124A, 124B also each have ballast rail teeth 133A, 133B that are disposed at respective ends of the sidewalls 124A, 124B. The ballast rail teeth 133A, 133B are designed to dig into and secure a flange 68’, 70’ of an X- rail-60B that may extend adjacent to the low side attachment mechanism 120. This also creates an electrical grounding / bonding path. Although an X-rail 60B is not shown in the drawings engaged with the ballast rail teeth 133A, 133B in the drawings, one will understand that an X- rail 60B may extend adjacent to the low side attachment mechanism 120, so that it can be engaged with the teeth 133A, 133B and be used as a ballast rail.

[0229] Figs. 24, 25, 27, and 28 show the seat 134. The seat 134 includes opposing mounting sections 136A, 136B that are designed to receive a portion of the opposing sidewalls 124A, 124B of the bracket 124 and a portion of the claw 154. The opposing mounting sections256959312.DOCXAttorney Docket No. 10089-2505754136A, 136B are arranged to support a bottom side of the solar panel module P during and after the mounting process. The opposing mounting sections 136A, 136B define seat apertures 138A, 138B that are each aligned with a corresponding bracket apertures 126 A, 126B. Although not shown, the bracket apertures 126 A, 126B and the seat apertures 138A, 138B may be arranged to receive a bolt, rivet, or a pin therethrough, or they may be extruded holes. This connection may further define the rotation axis Rl, which will allow the seat 134 to rotate relative to the bracket 122. A bottom wall 140 extends between the opposing mounting sections 136A, 136B and defines a deflecting tab 142 that is configured to engage with corresponding features on the claw 154. Extending from the top of both of the opposing mounting sections 136A, 136B are module support wings 144 A, 144B. The module support wings 144 A, 144B are arranged to support the solar panel module P during the mounting process.

[0230] The opposing mounting sections 136A, 136B include a top wall 146A, 146B, an outer wall 148A, 148B, and an inner wall 149A, 149B. The inner walls 149A, 149B extend from opposing sides of the bottom wall 140. The top walls 146A, 146B extend from the inner walls 149A, 149B in a direction away from the bottom wall 140. The outer walls 148A, 148B extend downward from top walls 146A, 146B in the direction of the bottom wall 140. In each opposing mounting sections 136A, 136B, each of these three walls 146A, 148A, 149A; 146B, 148B, 149B define claw receiving spaces 151 A, 15 IB that receive portions of the claw 154 therein. The outer walls 148A, 148B define the seat apertures 138A, 138B. As shown, both of the top walls 146A, 146B and the outer walls 148A, 148B define bracket slots 150A, 150B. The bracket slots 150A, 150B receive the top portions 128A, 128B of the bracket 122, so that the top portions 128A, 128B can extend beyond the top walls 146A, 146B to contact the solar panel module P. It is contemplated that only the top walls 146A, 146B may define the bracket slots 150A, 150B. The top walls 146A, 146B are also arranged to contact the solar panel module P during and after mounting.

[0231] Figs. 24, 25, and 29 show the claw 154. The claw 154 includes an upper portion 156 and a lower portion 158 opposing the upper portion 156 to define a mounting space 162 therebetween. The mounting space 162 is sized to receive both the bottom wall 140 of the seat 134 and the solar panel module P. The lower portion 158 includes locking teeth 160 extending along part of its length. The locking teeth are arranged into two rows 164 A, 164B, and these rows 164 A, 164B are arranged to engage with the deflecting tab 142 on the bottom wall 140 of the seat 134. The rows of teeth 164A, 164B and the parts of the lower portion 158 to which they are attached may be understood as being different segments of the lower portion 158. A266959312.DOCXAttorney Docket No. 10089-2505754 gap 166 is defined between the rows of teeth 164A, 164B, which may help space the teeth 164A, 164B, so that they engage with ends of the deflecting tab 142.

[0232] With reference to Figs. 30A-30D, the process of mounting a solar panel module P to the low side attachment 120 will now be described. First, as shown in Fig. 30A, the seat 134 is rotated relative to the bracket 122, so that the rear side of the solar panel module P is directed downward onto the module support wings. In this position, there may be some contact between the top portions 128A, 128B of the bracket 122 and the solar panel module P. Second, the claw 154 is moved over the seat 134 and the bottom side of the solar panel module P, so that the bottom wall 140 of the seat 132 and the bottom side of the solar panel module P are received within the mounting space 162 formed between the upper portion 156 and lower portion 158 of the claw 153. As this occurs, the locking teeth 160 slide over and engage with the deflecting tab 140 formed in the bottom wall 140 of the seat 134. The engagement between the teeth 160 and deflecting tab 140 secures the claw 152 to the seat 134. The strength and resiliency of the teeth 160 and deflecting tab 140, and the claw 152 and seat 134 more generally, are such that outside forces, such as weather, cannot disengage the teeth 160 from the deflecting tab 140. Figs. 30B1 and 30B2 show the claw 152 fully engaged with solar panel module P and seat 134. Because the claw 152 has a number of teeth 160 along its rows 164A, 164B, the claw 152 can become fully engaged with the solar panel module P and the seat 134 at any position along the rows 164A, 164B, so long as the teeth 160 are engaged with the deflecting tab 140. This allows for solar panel modules P of different sizes to be secured to the low side attachment 120. For example, frames of the solar panel modules P often come in different sizes depending on various needs. This means that many solar panel modules P having varying sizes of frames can be mounted to the same low side attachment 120. Third, as shown in Fig. 30C, the seat 134, claw 152, and solar panel module P are rotated about the rotation axis R1 in the direction of the arrows. During rotation, the position of solar panel module P within the seat brings the bottom wall of the module P into contact the top portions 128 A, 128B of the bracket 122 and the top walls 146A, 146B of the opposing mounting sections 136A, 136B of the seat 134, if it has not happened already. Fourth and finally, the rotation of the seat 134, claw 152, and solar panel module P brings an opposing side of the solar panel module P (not shown) into the proximity of the high side attachment mechanism 170, where additional steps will be taken to secure the solar panel module P to the high side attachment mechanism 170. At this point, low side mounting is complete. The mounted position is shown in Fig. 30D.

[0233] High Side Attachment276959312.DOCXAttorney Docket No. 10089-2505754

[0234] With reference to Figs. 31-36, the high side attachment mechanism 170 and its relevant features will now be described. The high side attachment mechanism 170 includes a pedestal 172 that is connected to the Y-rail 60, an attachment piece 192, and a fastener 200 to fully secure the attachment piece 192 to a mounting section 178 of the pedestal 172 and the solar panel module frame P. A bottom wall of the solar panel module frame P is supported by the pedestal 172, and a module engaging portion 194 of the attachment piece 192 is designed to secure the bottom wall of the module P to the attachment piece 192, in the mounting process (shown in Figs. 37A-37C).

[0235] Figs. 31-35 show the pedestal 172. The pedestal 172 includes a base 174 (shown in Figs. 31 and 32) that is connected to the Y-rail 60A, a support structure 176 extending from the base 174, and a mounting section 178 (shown in Figs. 31 and 33-35) extending from the support structure 176. The base 174 includes a body 208 defining a base aperture 210 proximate an end of the base 208. The base aperture 210 is aligned with the first mounting hole 84 on the Y-rail 60 A, so that a fastener 212 can be used to secure the base 174 to the Y- rail 60 A. A toe 211 extends from an end of the body 208 that opposes the end next to the base aperture 210. The toe 211 extends downward from the body 208 and partially at an angle relative to a plane defined by the body 208, so that it can be secured within the toe slot 92 of the Y-rail 60A. The toe 211 terminates with a substantially flat end that helps to retain the pedestal 172 within the Y-rail 60 A. The shape of the toe 211 makes it so that the toe 211 can be the first part of the pedestal 172 that engages with the Y-rail 60 A during the process of connecting the pedestal 172 to the Y-rail 60A. In this process, the toe 211 is first inserted into the toe slot 92 and then the rest of the pedestal 172 is rotated about the toe 211 and the toe slot 92 until a bottom face of the body 208 contacts the top surface of the Y-rail 60A. The first mounting hole 84 is arranged relative to the toe slot 92, so that when the bottom face of the body 208 contacts the top surface of the Y-rail 60A, the base aperture 210 is aligned with the first mounting hole 84. At this point, the fastener 212 can be inserted into the base aperture 210 and the first mounting hole 84. A clamp 214 extends from the end of the body 208 proximate to the base aperture 210. The clamp 214 can be used to contact a flange 68’ 70’ of an X-rail 60B to help secure the X-rail 60B to the Y-rail 60 A. This allows the clamp 214 secure the X-rail 60B in locations along the Y-rail 60 A where a ballast rail support clip 100 may not be present. This is shown in Fig. 31. It is contemplated that the system 10 may have an X-rail 60B that is secured to the Y-rail 60A via the clamp 214 and not the ballast rail support clip 100. This allows three X-rails 60B to be secured to the Y-rail 60A while only two ballast rail support286959312.DOCXAttorney Docket No. 10089-2505754 clips 100 are used. This allows for two rows of ballast blocks 114 to be arranged in the system 10, with only two support clips 100.

[0236] The support structure 176 extends from the base body 208 between the base aperture 210 and the toe 211. As shown, the support structure 176 is made of a variety of support beams that extend upward at different angles. However, other arrangements of support beams or even a single support beam or a single sheet of material strong enough to support the module P may be used. The base aperture 210 may also be arranged at different locations along the body 208 relative to the support structure 176 and its beams.

[0237] The mounting section 178 is located at the top of the support structure 176, opposite the base 174. As shown in Figs. 34 and 35, the mounting section 178 includes a support platform 180 near the top and an attachment platform 182 disposed below the support platform 180. When viewed from the top of the pedestal 172, both the support platform 180 and the attachment platform 182 extend in the same direction as the Y-rail 60A. When viewed from the side, as shown in Fig. 35, the top surfaces of the support platform 180 and the attachment platform 182 may be angled relative to the Y-rail 60A, meaning that the top surfaces may not be parallel to the top surface of the Y-rail 60 A. However, in some embodiments, the top surfaces of support platform 180 and the attachment platform 182 and / or the entireties of the support platform 180 and attachment platform 182 may extend parallel to the Y-rail 60A in both directions.

[0238] The attachment platform 182 includes an aperture 184 located a distance away from the support platform 180 to allow access to the aperture 184. A tilted extension 186 extends from an end of the attachment platform 182 and is angled upward relative to the top surface of the support platform 180. A mounting lip 188 extends upward from an end of the support platform 180. A sloped platform 190 extends in a direction away from the support platform 180 and the attachment platform 182 and includes a top surface that is angled downward, in the direction of the Y-rail 60 A.

[0239] Figs. 31, 33, 34, and 36 show the attachment piece 192. The attachment piece 192 includes a module engaging portion 194 and a pedestal engaging portion 196 disposed opposite of the module engaging portion 194. The pedestal engaging portion 196 includes a slot 198 defined in a top surface. Inner lips 207A, 207B are arranged under the surface defining the slot 198. The module engaging portion 194 includes teeth 202 configured to contact and dig into the solar panel module P when it is mounted to the high side attachment mechanism 170. Sloped surfaces 204 extend under the teeth 202 to define a mounting space 206 therebetween.296959312.DOCXAttorney Docket No. 10089-2505754The sloped surfaces 204 extend to a part of the pedestal engaging portion 196 that is adjacent to the surface that defines the slot 198.

[0240] The attachment piece 192 is shaped to fit around the mounting portion 178 of the pedestal 172. The pedestal engaging portion 196 fits around the attachment platform 182, so that the slot 198 of the pedestal engaging portion 196 is aligned with the aperture 184 on the attachment platform 182. This allows a fastener 200 to secure the pedestal engaging portion 196 to the attachment platform 182. The fastener 200 can sit within the slot 198 and the aperture 184 without being completely tightened. This allows the attachment piece 192 to slide along the mounting section 178 to change the position of the attachment piece 192. Depending on the size of the frame of the solar panel module P that is to be mounted, the relative position of attachment piece 192 on the mounting section 178 can be changed prior to the mounting of the solar panel module P. This allows solar panel modules P and frames of different sizes to be mounted to the same high side attachment mechanism 170. This also allows the end of the pedestal engaging portion 196 to contact or be supported by the tilted extension 186 at different locations along the length of the tilted extension.

[0241] The shape of the attachment piece 192 may also allow the attachment piece 192 to be held on the mounting section 178 without the fastener 200. In this example, the attachment piece 192 is deformable to fit over the mounting section 178, but features such as the inner lips 207A, 207B are designed to contact an inner portion of the attachment platform 182 to prevent the attachment piece 192 from falling off the mounting section 178. The tilted extension 186 and the sloped platform 190 are also sized to limit rotation of the attachment piece 192 relative to the mounting section 178. The sloped platform 190 also keeps the attachment piece 192 secured to the mounting section 178 when a high uplift load is experienced. The bottom of the attachment piece 192 may have flanges that engage with the sloped platform 190 to allow for this. Without the fastener 200, the attachment piece 192 can rotate about the mounting section 178, but at least one of the tilted extension 186 and the sloped platform 190 can contact interior parts of the attachment piece 192 to prevent rotation beyond a certain point.

[0242] With reference to Figs. 37A-C, the process of mounting solar panel module P to the high side mechanism 170 will now be described. As mentioned above in connection with the low side attachment mechanism 120, the mounting process related to the high side mechanism 170 occurs after the solar panel module P has been mounted to the low side attachment mechanism and rotated into the proper position. Fig. 37A shows the solar panel module P being moved downward in the direction of the support platform 180. Fig. 37B shows the bottom wall of the solar panel module P in contact with the support platform 180 and the mounting lip306959312.DOCXAttorney Docket No. 10089-2505754188. The fastener 200 is slightly exposed above the pedestal engaging portion 196, meaning the fastener 200 is not fully tightened within the slot 198 and aperture 184. As shown in this position, the module engaging portion 194 of the attachment piece 192 is arranged such that the teeth 202 are located slightly above or just in contact with the solar panel module P. The attachment piece 192 may be moved by an installer, by sliding it along the length of the slot, into this position. However, other arrangements of the module engaging portion 194 are possible depending on how much of the fastener 200 is exposed above the pedestal engaging portion 196 and where exactly along the slot 198 the fastener 200 is be located. To fully secure the solar panel module P to the high side attachment mechanism, the fastener 200 is further tightened within the slot 198 and aperture 184. When the fastener 200 begins to tighten, it causes the attachment piece 192 to tilt relative to its previous position relative to the attachment platform 182. As the fastener 200 continues to tighten, the surface of the pedestal engaging portion 196 that defines the slot 198 is pressed against the attachment platform 182. This causes the entire attachment piece 192 to move in the downward, towards the support structure 176, which causes the teeth 202 to engage with and dig into the solar panel module frame P. This is represented by the arrows in Fig. 37C.

[0243] In another embodiment, the attachment piece 192 may be configured to rotate about the tilted extension 186 or the aperture 184 as the fastener 200. In this embodiment, the attachment piece may be arranged, so that there is a gap between the bottom surface of the pedestal engaging portion 196 that defines the slot 198. When the fastener 200 is tightened a first amount, the pedestal engaging portion is driven in the direction of the attachment platform 182, closing the gap and placing the bottom surface of the pedestal engaging portion 196 that defining the slot 198 into contact with the top surface of the attachment platform 182. This rotates the module engaging portion 194 slightly upward relative the solar panel module P, so that the teeth 202 move over top the solar panel module P, and the solar panel module P can be received within the mounting space 206. At this point, the fastener 200 still has not been tightened to completely secure the pedestal engaging portion against the attachment platform 182. In this position, the attachment piece 192 can still slide relative to the mounting section 178 along the length of the slot 198. An installer can then slide the attachment piece 192, so that the solar panel module P is received within the mounting space, with the teeth 202 being arranged slightly above or just in contact with the solar panel module P. Then, the fastener 200 is tightened a second amount, driving pedestal engaging portion into contact with the attachment platform 182, which causes the teeth 202 to engage with and dig into the solar panel module P, securing it against the support platform 180, as described above. This also rotates316959312.DOCXAttorney Docket No. 10089-2505754 the pedestal engaging portion 196 relative to the attachment platform 182. When this occurs, the wall of the pedestal engaging portion 196 that defines the slot 198 contacts more of the top surface of the attachment platform 182 relative to its previous position. In some embodiments, this wall may fully contact the top surface of the attachment platform 182, so that the slot 198 is parallel to the top surface of the attachment platform 182.

[0244] Wind Deflector

[0245] With reference to Figs. 38-48, different embodiments of a wind deflector assembly 219, 233 are shown. Both assemblies 219, 233 can be secured to a back end, also known as a north end, of the system 10, and both 219, 233 use part of the pedestal 172 to be secured to a foot 12 and / or the Y-rail 60A. The pedestal 172 includes a wind deflector arm 216 extending from the support structure 176. The wind deflector arm 216 terminates with a curved clip 218 that is used to mount wind deflectors 224 thereto. The curved clip 218 defines a first mounting segment 220 and a second mounting segment 222 that are essentially in line with each other, so that two wind deflectors 224 A, 224B can be mounted to the clip 218 in an overlapping manner to ensure that there are no gaps.

[0246] With reference to Figs. 38-41, wind deflector assembly 219 is shown. The wind deflector assembly 219 includes wind deflectors 224 A, 224B, which are the same, but are mounted in opposite orientations. The wind deflectors 224 include a body 230 that extends between a first end 226 and a second end 228. The first end 226 defines a number of slots (not numbered) that receive a fastener to secure the wind deflector 224 to a mounting point. The second end 228 is shaped to be received within either the first mounting segment 220 or the second mounting segment 222 of the curved clip 218. One of the mounting points for the first end 226 can be located at attachment platform 182 of the high side attachment mechanism 184, where the fastener 200 can extend through one of the slots. Another mounting point for the first end 226 can be at a foot 12, where the fastener of the foot 12 and Y-rail 60 A can extend through one of the slots. Although the Y-rail 60A is not shown in Fig. 39, it is intended to be used in that figure similar to how it is shown in Figs. 38 and 42-48. In the wind deflector assembly 219, a first wind deflector 224A is arranged, so that the first end 226A is secured to the fastener 200 against the slot 198 defined the attachment piece 192, and the second end 228 A is secured to first mounting segment 220. A second wind deflector 224B is arranged, so that the first end 226 is mounted to the Y-rail 60A and foot 12, and the second end 228B is secured to the second mounting segment 222.

[0247] With reference to Figs. 42-48, wind deflector assembly 233 is shown. This assembly 233 includes a third wind deflector 224 A’. The assembly 233 still uses the pedestal326959312.DOCXAttorney Docket No. 10089-2505754172 of the high side attachment mechanism 170, but the pedestal 172 is not used to mount a solar panel module P and no attachment piece 192 is present. Instead, a wind deflector support 234 is connected to the mounting section 178. The wind deflector support 234 includes a base 236 that extends over the support platform 180. A first platform clip 238 extends from the base 236 and contacts the attachment platform 180, extending over the mounting lip 188. The first platform clip 238 may define an aperture (not numbered) that aligns with the aperture 184 in the attachment platform 182, so that the fastener 200 can secure the second platform clip 238. A second platform clip 248 extends from the base 236 and is secured against the sloped platform 190. A support structure 242 extends from the base and terminates with a top mount 244. The top mount 244 defines another aperture 246.

[0248] The first and second wind deflectors 224A, 224B are secured in the same manner discussed above. A third wind deflector 224A’ is aligned in the same manner as the first wind deflector 224A. The first end 226A’ is arranged so that one of its slots is aligned with the aperture 246 in the mount 244, so that the first end 226A’ can be secured to the mount 244 via a fastener (not shown). The second end 228B’ is received by the first platform clip 238, so that it is secured against the support structure 242.

[0249] With reference to Figs. 49-51, a high load assembly 250 is shown. The high load assembly 250 is used to support an underside of the solar panel module P to provide extra support if and when snow accumulates on the surface of the module P. The high load assembly 250 includes a load bar 252 that is arranged at the same angle as the surface of the solar panel module P to provide this support. The load bar 252 is supported by a minor support post 254 and a major support post 256. As shown, the support posts 254, 256 include two legs, with the minor support post 254 having legs 266A, 266B and major support post 256 having legs 268A, 268B. However, any arrangements that support the functionality of the high load assembly 250 may be used. The major support post 256 is longer than the minor support post 254 to account for sloped nature of the solar panel module P. Bar platforms 270, 272 are respectively provided at the tops of the support posts 254, 256 to contact the load bar 252. Bases 258, 260 are respectively provided at the ends of the support posts 254, 256. The bases 258, 260 contact the Y-rail 60A, and respectively define apertures 262, 264. The apertures 262, 264 are aligned with the high load holes 88 formed in the top wall of the Y-rail 60A to receive fasteners to secure the bases 258, 260 to the Y-rail 60A. The load bar 252 includes a body 274 and sidewalls 276A, 276B extending downward from the body in the direction of the support beams 254A, 254B. Flanges 278A, 278B extend inward respectively from the sidewalls 276A, 276B that can help retain the bar platforms 270, 272 within the load bar 252.336959312.DOCXAttorney Docket No. 10089-2505754

[0250] System 300

[0251] In Figs. 52-90, a second solar panel module system 300 and its components are shown. Examples of these components working together to support a single solar panel module P is shown in Fig. 52. A four-panel solar panel array using the system 300 is shown in Figs. 85-88.

[0252] One will appreciate that larger solar panel arrays can be created using this system 300. The specifics of the system 300 and its components are discussed in greater detail below. It will become apparent that some features of this system 300 are similar to those of the first system 10. For example, a solar panel module P is secured to a low side attachment mechanism 402 of system 300 via rotation like the low side attachment mechanism 120 of system 10. The general structure of the features of the low side attachment mechanism 402 are also similar. These similar features of system 300 will not be discussed in the level of detail as they were in connection with system 10. In another example, different apertures 354, 356A, 356B, 358, 360, 362 are defined along a mounting rail 342. These apertures 354, 356A, 356B, 358, 360, 362 are spaced along the mounting rail 342 to facilitate the consistent alignment between overlapping mounting rails 344 and / or a support rail 322 during the assembly of the system 300. This is similar to the placement of the apertures 82, 84, 86, 88, 90 along the Y-rail 60A in system 10. One will appreciate the structures and functionalities of these and other features given the description provided in system 10. Additionally, some of the features of system 300 are the same as or similar to those discussed in U.S. Patent Application Serial No. 18 / 244,887 and International Patent Application No. PCT / US2024 / 045920, the disclosures of which are hereby incorporated by reference in their entireties.

[0253] Foot

[0254] With reference to Figs. 53-56, an example of a foot 302 used in system 300 is shown. The foot 302 includes a body 304, defining a top face 306 and a bottom face 308. The top face 306 is used to secure a support rail 322 to the foot 302, and the bottom face 308 is used to contact the roof. The body 304 includes pedestals 310 that extend from the bottom face 308 and are used to secure the support rail 322 to the foot 302. Extending across the body 304 and between two opposing pedestals 310 are upper support surfaces 312 and lower support surfaces 314. The lower support surfaces are arranged in rows on different sides of the upper support surfaces 312, so as to flank the upper support surface 312. Sloped surfaces 316 connect each upper support surfaces 312 to the respective flanking lower support surfaces 314A, 314B. This means that first lower support surfaces 314A extend between one pedestal 310 and one upper support surface 312, and second lower support surfaces 314B extend between each upper346959312.DOCXAttorney Docket No. 10089-2505754 support surface 312 and the opposing pedestal 310. A mounting lip 318 extends from each pedestal 310 to form mounting spaces 320 between each mounting lip 318 and its respective lower support surface 314.

[0255] Support Rail

[0256] With reference to Figs. 56 and 57, the support rail 322 and its connection to the foot 302 will now be described. The support rail 322 includes an elongated body 324 extending over the length of two feet 302. The elongated body 324 has a top wall 323 and sidewalls 325 A, 325B extending from opposite sides of the top wall 323. Side flanges 326A, 326B respectively extend from ends of the sidewalls 325 A, 325B. The flanges 326A, 326B include a first portion 328A, 328B, extending substantially or nearly perpendicular to ends of the sidewalls 325A, 325B, and a second portion 330A, 330B extending downward from the first portion 328A, 328B. At different points along the length of the support rail 322, connecting lips 332 extend upward from the first portions 328A, 328B of the flanges 326A, 326B to form connecting spaces 334 with their respective sidewalls 325A, 325B. At different points along the length of the support rail 322, rail holes 336, 337 are formed within the top wall 323 and the sidewalls 325A, 325B. As shown, rail holes 336 are formed within the top wall 323, and rail holes 337 are formed within the sidewalls 325 A, 325B. The rail holes 336, 337 are arranged to be aligned with corresponding holes 360, 362 formed in the mounting rail 342 to facilitate the connection between the support rail 322 and one or more mounting rails 342. Recessed guides 339 are also formed along the elongated body 324 between the top wall 323 and one of the sidewalls 325A, 325B. As shown, pairs of recessed guides 339 are aligned along the body 324, across from one another, so that a first recessed guide 339 is formed between the top wall 323 and sidewall 325A, and a second recessed guide 339 is formed between the top wall 323 and sidewall 325B. These help an installer secure a mounting rail 342 to the support rail 322, which will be discussed below.

[0257] The support rail 322 is supported on the foot 302 via contact with the upper support surfaces 312 and the lower support surfaces 314A, 314B. Specifically, the first portions 328A, 328B of the flanges 326A, 326B are supported by the outer ends of the upper support surfaces 312. The second portions 330A, 330B of the flanges 326A, 326B are composed of first downwardly extending subsections 331 A, 33 IB and second horizontally extending subsections 333 A, 333B. The first downwardly extending subsections 331 A, 33 IB are supported by the sloped surfaces 316 and the second horizontally extending subsections 333 A, 333B are supported by the lower support surfaces 314A, 314B. The pedestals 310 are arranged, so that the second portions 330A, 330B contact the pedestals 310 and create a frictional fit with the356959312.DOCXAttorney Docket No. 10089-2505754 pedestals. The ends of the second portions 330A, 330B are arranged to fit within the mounting spaces 320 formed between the mounting lips 318 and their respective lower support surfaces 314A, 314B. The mounting lips 318 may also contact the second portions 330A, 330B to further secure the support rail 322 to the foot 302. The mounting lips 318 may be flexible and resilient such that as the support rail 322 is installed on the foot, the edges of the flanges 330A, 330B contact a sloping top surface of the mounting lips 318 which causes the mounting lips to deflect and bend away from the sloped surfaces 316 effectively opening the mounting spaces 320 allowing the flanges 330A, 330B to enter the mounting spaces 320. As the flanges 330A, 330B pass by the widest part of the mounting lips 318, the mounting lips 318 resiliently return to their normal position, capturing the flanges 330A, 330B in the mounting spaces 320.

[0258] Mounting Rail

[0259] With reference to Figs. 58 and 59, a mounting rail 342 is shown. The mounting rail 342 includes an elongated body 344 extending between a first end 346 and a second end 348. The elongated body 344 includes a top wall 350 and sidewalls 352A, 352B extending from sides of the top wall 350. The sidewalls 352A, 352B terminate with rounded ends 353 A, 353B that curve upward to overlap parts of their respective sidewalls 352A, 352B. The top wall 350 and sidewalls 352A, 352B define different apertures for facilitating connections with different attachment mechanisms, such as a low side attachment 402 and high side attachment 450.

[0260] A first example of these apertures are adjacent slots 354, which are located proximate the first end 346 of the mounting rail 342. The adjacent slots 354 are each designed to receive a flexible locking clip 412 of a bracket 404 of the low side attachment mechanism 402 therein. A number of adjacent slots 354 are provided to allow for the low side attachment mechanism 402 to be arranged at different positions along the mounting rail 342. The series of positions enabled by the series of slots 354 enable the accommodation of variously sized solar modules P while maintaining the nominal panel slope of the system 300. A second example of apertures are ballast rail support clip holes 358, which are disposed along the length of the top wall 350. The ballast rail support clip holes 358 are used to align a ballast rail support clip 372 to the mounting rail 342. The ballast rail support clip 372 is secured to the mounting rail 342 through an extruded hole that extends into ballast rail support clip holes 358. Alternatively, the ballast rail support clip 372 is secured to the mounting rail 342 via a fastener. Multiple ballast rail support clip holes 358 are provided; however, not all will be used at a single time. To support a ballast block 114, at least two ballast rail support clips 372 can be secured to the mounting rail 342 via at least two ballast rail support clip holes 358. Each clip 372 can support one or two ballast rails 394, allowing the ballast block 114 to extend between366959312.DOCXAttorney Docket No. 10089-2505754 adjacent ballast rails 394. The arrangement of multiple ballast rail support clip holes 358 also allows for multiple ballast rail clip 372 and ballast rail 394 positions or spacings to support varying sizes of ballast blocks to be used with the mounting rail 342. A third example of apertures are high side mounting holes 356A, 356B, which are provided in the sidewalls 352A, 352B proximate the second end 348. The high side mounting holes 356A, 356B are arranged to receive extruded holes 456A, 456B formed in the tilt arm 452 of the high side attachment mechanism 450. A fourth example of apertures are overlapping holes 360, 362 that are provided proximate the first end 346 and the second end 348. The overlapping holes 360, 362 are arranged to align with corresponding support rail holes 336, 337 in the support rail 322. Specifically, overlapping holes 360 are formed in the top wall 350 and are arranged to align with support rail holes 336. Overlapping holes 362 are formed in the sidewalls 352A, 352B and are arranged to align with support rail holes 337. These corresponding holes 336, 337, 360, 362 can be connected with a fastener to secure the mounting rail 342 to the support rail 322. The corresponding holes 336, 337 360, 362 may also be connected via extrusions. For example, the holes 362 in the sidewalls 352A, 352B of the mounting rail 342 may be extruded, so that the extruded part can be received within the support rail holes 336. Overlapping holes 362 may be extruded holes that are received by the corresponding support rail holes 337. The ends 353A, 353B of the sidewalls 352A, 352B are received within the connecting spaces 334 and the connecting lip prevents the bending of the sidewalls 352A, 352B and thus the withdrawal of extruded holes 362 from rail holes 337.

[0261] As already described, some holes / apertures may simply be used as alignment indicators, so that an installer knows where exactly to align a specific feature, such as the mounting rail 342 relative to the support rail 422 for proper assembly. Other holes / apertures may be extruded holes, where one hole / aperture is extruded away from its respective body or wall, so that it may fit within a corresponding hole / aperture. Other holes / apertures are arranged to receive a fastener to secure two features together. One will appreciate that at least some holes / apertures formed in adjacent features that may not otherwise be in constant contact, will receive a fastener to form a secure, surface-to-surface connection, such as overlapping holes 360 and support rail holes 336 in the mounting rail 342 and support rail 322. Not only does this secure features against each other, but it also creates an electrical pathway that can be used for grounding in the event of an electrical failure in the photovoltaic module or a lightning strike.

[0262] The tops of the sidewalls 352A, 352B and top wall 350 are profiled to facilitate connections with the different features mentioned above. Specifically, the sidewalls 352A,376959312.DOCXAttorney Docket No. 10089-2505754352B form curved sections 364A 364B as the sidewalls 352A, 352B extend away from the top wall 350. The curved sections 364A, 364B respectively define clip spaces 365A, 365B that extend partially under the top wall 350. The clip spaces 365A, 365B allow for corresponding connection features of other components to be secured within the clip spaces 365 A, 365B and / or against the curved sections 364A, 364B. This is one way to allow these other components to be secured to the mounting rail 342, some of which are discussed below. The curved sections 364A, 364B also define support rail faces 366A, 366B that are arranged to contact the top wall 323 of the support rail 322.

[0263] The bottoms of the sidewalls 352A, 352B are also profiled to facilitate connections with the support rail 322 and the tilt arm 452 of the high side attachment mechanism 450. For example, the ends 353 A, 353B of the sidewalls 352A, 352B are rounded to facilitate engagement with the connecting lips 332A, 332B and connecting spaces 334 formed in the support rail 322. Proximate the high side holes 356A, 356B, the ends 353 A, 353B define hems 355A, 355B and cut outs 357A, 357B that are used with the tilt arm 452, which will be discussed in greater detail below.

[0264] Fig. 60 shows a mounting rail 342 connected to the support rail 322, which is shown connected to a foot 302. The connection is formed between the ends of the sidewalls 352A, 352B and the connecting spaces 334 of the support rail 322. Specifically, the ends 353 A, 353B of the sidewalls 352A, 352B are arranged to fit within or wedge into the connecting spaces 334 to form a frictional fit with the sidewalls 325 A, 325B of the support rail 322 and the connecting lips 332. As noted above, a fastener may also be used within the rail hole 336 defined within the support rail 322 and an overlapping hole 360 formed within the top wall 350 of the mounting rail 342. In some embodiments, apertures or holes formed in the sidewalls 325A, 325B, 352A, 352B of the rails 322, 342 may be used to further secure these features. Mounting rails 342 are flexible enough, so that their sidewalls 352A, 352B can flex outward to fit around the support rail 322 and mount in the manner shown in Fig. 60. The flexing of the sidewalls 352A, 352B is promoted by the presence of the recessed guides 339 formed in the support rail 322.

[0265] Ballast System

[0266] With reference to Fig. 61 and 62, a ballast rail support clip 372 is shown. The ballast rail support clip 372 has a first rail support portion 374 extending along a side of the ballast rail support clip 372. A second rail support portion 376 is also provided and extends along a side of the ballast rail support clip 372 that is opposite the side of the first rail support portion 374. A first rail mounting clip 378 extends from the first rail support portion 374, and a second386959312.DOCXAttorney Docket No. 10089-2505754 rail mounting clip 380 extends from the second rail support portion 376. A central segment 382 extends between the first rail support portion 374 and the second rail support portion 376. The central segment 382 is connected to the first rail support portion 374, but it may also be connected to the second rail support portion 376. The central segment 382 is located approximately at the center of the ballast rail support clip 372. Near the center, the central segment 382 defines a central aperture 384 that is configured to align with a ballast rail support clip hole 358 on the mounting rail 342 to receive a fastener. The fastener is one way to secure the ballast rail support clip 372 to the mounting rail 342. The central aperture 384 may be an extruded hole that extends downwardly into the rail support clip hole 358. This can lock the ballast rail support clip onto the mounting rail in one of the ballast rail positions.

[0267] A first ballast rail mount 386 and a second ballast rail mount 388 are provided at opposing ends of the ballast rail support clip 372 which are perpendicular to the sides along which the first and second rail support portions 376, 374 extend. The first and second ballast rail mounts 386, 388 extend above the first and second rail support portions 376, 374 and generally extend in a direction opposite that in which the first and second rail mounting clips 378, 380 extend. The first and second ballast rail mounts 386, 388 are designed to receive opposing side flanges 396, 398 of one or more ballast rails 394.

[0268] To receive the side flanges 396, 398, the first ballast rail mount 386 defines a first lower receiving space 390 A and a first upper receiving space 392 A. Both of these receiving spaces 390 A, 392 A can receive one of the flanges 396, 398. The first lower receiving space 390A is arranged relative to the first and second rail support portions 374, 376, so that the ballast rail 394 can be supported by the first and second rail support portions 374, 376 when the side flange 396, is received within the first lower receiving space 390A. Tabs 391A are also defined within the first ballast rail mount 386 to separate the first lower receiving space 390 A from the first upper receiving space 392 A. The top surfaces of the tabs 391 A can partially define the first upper receiving space 392 A. The first upper receiving space 392 A is arranged to receive a side flange 396’ of a second ballast rail 394’ therein. An underside of the side flange 396’ is supported by the top surface of the tab 391 A. The second ballast rail mount 388 has the same features of the first ballast rail mount 386. Specifically, the second ballast rail mount 388 defines a second lower receiving space 390B and a second upper receiving space 392B, which are separated by a tab 391 A. The second lower receiving space 390B is arranged relative to the first and second rail support portions 374, 376, so that the ballast rail 394 can be supported by the first and second rail support portions 374, 376 when the side flange 398, is received within the first lower receiving space 390 A. The second upper receiving space 392B396959312.DOCXAttorney Docket No. 10089-2505754 is arranged to receive a side flange 398’ of a second ballast rail 394, with the side flange 398’ being supported by the top surface of the tab 391B. Each ballast rail mount 386, 388 define lead-in surfaces 393 A, 393B above the upper receiving spaces 392 A, 392B to guide an installer in securing a ballast rail 394 to the ballast rail support clip 372.

[0269] As shown, the first and second lower receiving spaces 390 A, 390B can be thought of different ways. In one example, the first and second lower receiving spaces 390A, 390B can be thought of as extending laterally along the widths of their respective ballast rail mounts 386, 388 and extending vertically from the plane defined by the top surfaces of the first and second rail support portions 374, 376 to bottom surface of the respective tabs 391 A, 391B. The first and second upper receiving spaces 392 A, 392B can be thought of as extending laterally along the widths of their respective ballast rail mounts 386, 388 and extending vertically between the top surfaces of their respective tabs 391 A, 391B to the adjacent surface defined in the ballast rail mounts 386, 388. In another example, the first and second lower receiving spaces 390 A, 390B can be thought of as the two notches or slots defined at the bottoms of their respective ballast rail mounts 386, 388. The first and second upper receiving spaces 392A, 392B can be thought of as the two upper notches or slots defined in their respective ballast rail mounts 386, 388. In either instance, the functionality of the four receiving spaces 390A, 390B, 392A, 392B is the same. In other embodiments, the tabs 391 A, 391B of first and second ballast rail mounts 386, 388 may extend along the entire width of the first and second ballast rail mounts 386, 388 to further define the four receiving spaces 390A, 390B, 392A, 392B along the widths of the rail mounts 386, 388. In other embodiments, the first and second ballast rail mounts 386, 388 may essentially be solid features, like a block, with the four receiving spaces 390 A, 390B, 392 A, 392B being defined therein.

[0270] Figs. 63 and 64 show the ballast rail support clip 372 secured to a mounting rail 342. As mentioned above, the central aperture 384 of the ballast rail support clip 372 can be an extruded hole that is aligned with and extends into a ballast rail support clip hole 358 defined in the top wall. Alternately the central aperture 384 and the clip hole 358 may be concentrically aligned and configured to receive a fastener to secure the ballast rail support clip 372 to the mounting rail 342. The first mounting rail clip 378 and second mounting rail clip 380 are both shaped to extend into one of the clip spaces 365A, 365B of the mounting rail 342. The ballast rail support clip 372 is flexible, so that the first and second mounting rail clips 378, 380 can extend over the top wall 350 of the mounting rail 342 and then snap or click into place within the clip spaces 365A, 365B. This is another way to secure the ballast rail clip 372 to the mounting rail 342.406959312.DOCXAttorney Docket No. 10089-2505754

[0271] Fig. 65 shows the ballast rail 394. The ballast rail 394 has an elongated body 395 with side flanges 396, 398 extending from opposing sides of the body 395.

[0272] With reference to Figs. 66-70, the ballast rail support clips 372 are shown secured to the mounting rail 342 with different arrangements of ballast rails 394 and ballast blocks 114. Figs. 66 and 67 show a single ballast rail 394 secured to the ballast rail support clip 372. The side flanges 396, 398 are received within the first and second lower receiving spaces 390 A, 390B of the ballast rail support clip 372. The ballast rails 394 are also flexible, so that they can bend to allow the side flanges 396, 398 to be inserted into the first and second lower receiving spaces 390 A, 390B. When installing a ballast rail 394 to the ballast rail support clip 372, an installer may align the side flanges 396, 398 against the lead-in surfaces 393 A, 393B and then push the ballast rail 394 downward, in the direction of the receiving spaces 390 A, 390B, 392A, 392B. The shape of the lead-in surfaces 393 A, 393B pushes the side flanges 396, 398 inward, toward the elongated body 395. This flexes or bends the ballast rail 394, so that when the side flanges 396, 398 are aligned with the desired receiving spaces 390 A, 390B, 392A, 392B, the ballast rail 394 will unflex and side flanges 396, 398 can snap into the desired receiving spaces 390A, 390B, 392A, 392B. The ballast rails may be sized so that the side flanges 396, 398 may engage with the ballast rail mounts 386, 388 to create a friction fit between the ballast rail 394 and the ballast rail support clip 372. In some embodiments, a friction fit may not be present, and instead, the weight of the ballast blocks 114 are sufficient to keep the ballast rails 394 in place against the ballast rail support clips 372. When ballast blocks 114 are not placed on the ballast rails 394, the tabs 391 A, 391B can help prevent the side flanges 396, 398 from being displaced from the first and second lower receiving spaces 390 A, 390B.

[0273] Fig. 68 shows two ballast rails 394, 394’ overlapping one another within the ballast rail support clip 372. In this arrangement, the bottom ballast rail 394 has side flanges 396, 398 that are secured within the first and second lower receiving spaces 390 A, 390B. The top ballast rail 394’ has side flanges 396’, 398’ that are secured within the first and second upper receiving spaces 392A, 392B. The elongated bodies 395, 395’ are sized and shaped to allow for this overlap. The overlap creates ballast support surfaces that extend along a length in the X direction that is longer than the length of any one ballast rail 394, 394’. The ballast rails 394 and ballast support clips 372 are strong enough and resilient enough to support ballast blocks 114 along this entire, extended length. In other words, under the weight of the ballast blocks 114, the top ballast rail 394’ can be compressed against the bottom ballast rail 394 and still maintain the ability to support the ballast blocks 114.416959312.DOCXAttorney Docket No. 10089-2505754

[0274] Fig. 69 shows a single ballast block 114 extending between adjacent ballast rails 394. The ballast block 114 is supported by the first side flange 396 of a first ballast rail 394 and the second side flange 398 of a second ballast rail 394. The ballast rail support clip holes 358 are arranged along the mounting rail 342 to ensure that the ballast rail support clips 372 securing the adjacent ballast rails 394 are at the proper distance to facilitate the support of the ballast block 114.

[0275] Low Side Attachment

[0276] With reference to Figs. 71-79C, the low side attachment mechanism 402 and its mounting process will now be described, focusing on the differences between the low side attachment mechanism 402 and the low side attachment mechanism 120 already described in connection with system 10. The low side attachment mechanism 402 has the same general features as low side attachment mechanism 120 - a bracket 404, a seat 418, and a claw 428, with the seat 418, claw 428, and solar panel module P rotating about the bracket during the mounting process (shown in Figs. 79A-79C). The seat 418 is arranged to initially support the solar panel module P, and then the claw 428 is arranged to slide over the seat 418 and solar panel module P to secure the two together. After the claw 428 secures the solar panel module P to the seat 418, the claw 428, seat 418, and module P are rotated about a rotation axis R2 into the mounted position. Fig. 79C shows the low side attachment mechanism 402 in the mounted position and the rotation that occurs prior to this represented by arrows. A first arrow extends around the outside of the low side attachment mechanism 402 and solar panel module, and a second arrow extends around the rotation axis R2.

[0277] Figs. 71-74 show the bracket 404. The bracket 404 has opposing sidewalls 406A, 406B defining bracket apertures 407A, 407B that are extruded into the bracket 404 to define the rotation axis R2. Wings 408A, 408B extend from the opposing sidewalls 406A, 406B and have a top surface that is arranged to support the solar panel module P in the mounted position. Platforms 409A, 409B also extend from the opposing sidewalls 406A, 406B. The platforms 409A, 409B are shaped to allow the bracket 404 to receive and support other components of the low side attachment 402 during shipping. A rail wall 410 extends between the opposing sidewalls 406A, 406B and defines a flexible locking clip 412. The flexible locking clip 412 is arranged to be received within one of the adjacent slots 354 defined in the mounting rail 342. This is one way to position and secure the bracket 404 to the mounting rail 342. The bracket 404 also includes mounting legs 416 that are shaped to be received by the clip spaces 365A, 365B in the mounting rail 342. The mounting legs 416 are flexible to allow for them to snap426959312.DOCXAttorney Docket No. 10089-2505754 or click into the clip spaces 365 A, 365B. A tongue 414 extends from an end of the rail wall 410 and is arranged to secure the claw 428 relative to the bracket 404 to some degree.

[0278] Figs. 71, 72, 75, and 76 show the seat 418. The seat 418 includes module support surfaces 420A, 420B arranged to support the solar panel module P in different positions throughout the mounting process. The module support surfaces 420A, 420B are generally arranged to define a right angle between them. However, other angles may be formed between the two surfaces 420A, 420B. The shape of module support surface 420B is such that different angles may be formed with module support surface 420 at different points along module support surface 420B. It is apparent from the mounting process that one or both of the module support surfaces 420A, 420B will provide different levels of support to the solar panel module P at different times before, during, and after the mounting process.

[0279] Opposing sidewalls 422A, 422B extend from opposing ends of module support surface 420A. The opposing sidewalls 422A, 422B each define a seat aperture 423A, 423B. The seat apertures 423 A, 423B are arranged to receive the extruded portions of the bracket apertures 407A, 407B to connect the seat 418 to the bracket 404. This also allows the seat 418 to rotate about the rotation axis R2 defined by the bracket apertures 407A, 407B. Indents 424A 424B are formed in the opposing sidewalls 422A, 422B. The indents 424A, 424B are aligned along a shared axis and extend toward each other under the module support surface 420A. The indents 424 A, 424B are arranged to engage with corresponding features on the claw 428. The axis shared by the indents 424A, 424B may be parallel to the rotation axis R2 or it may be another angle, so long as the functionality of the low side attachment mechanism 402 can be maintained. Rows of locking teeth 426A, 426B are arranged to extend from the opposing sidewalls 422A, 422B. As shown, the locking teeth 426A, 426B extend toward each other, under module support surface 420A. The locking teeth 426A, 426B are arranged to engage with corresponding features on the claw 428.

[0280] Figs. 71, 72, and 77A-78 show the claw 428. The claw 428 has an upper portion 430 and a lower portion 432 that define a mounting space 434 therebetween. The mounting space 434 is sized to receive both the solar panel module P and module support surface 420A of the seat 418 in such a way that the claw 428 at least partially fixes these two features against one another. Opposing sidewalls 436A, 436B are present in the claw 428. The sidewalls 436A, 436B extend along both the upper portion 430 and the lower portion 432, but the majority of the sidewalls 436A, 436B are part of the lower portion 432. Within the lower portion 432, the sidewalls 436A, 436B define indent slots 438A, 438B and indent holes 439A, 439B. Both of these features are arranged to engage with the indents 424 A, 424B of the seat 418. The indent436959312.DOCXAttorney Docket No. 10089-2505754 holes 439 A, 439B are used with the indents 424 A, 424B to keep the claw 418 secured to the seat 418 in one position, and the indent slots 438 A, 438B are used with the indents 424 A, 424B to keep the claw 418 secured to the seat 418 along the length of the indent slots 438 A, 438B.

[0281] Flexible tabs 440A, 440B extend from the opposing sidewalls 436A, 436B in the lower portion 432. As shown, the flexible tabs 440A, 440B extend from ends of the opposing sidewalls 436A, 436B and essentially curl into the claw 428. This means that parts of the flexible tabs 440A, 440B extend adjacent and parallel to their respective sidewall 436A, 436B. From these parallel extensions, the flexible tabs 440A, 440B then extend back in the direction of their respective sidewalls 436A, 436B and terminate at end points below the upper portion 430. The end points are arranged to contact and engage with the locking teeth 426A, 426B on the seat 418. The opposing sidewalls 436A, 436B also include recessed surfaces 442A, 442B formed at the ends of the sidewalls 436A, 436B opposite the flexible tabs 440A, 440B. These allow a form or spot where an installer can press or squeeze the sidewalls 436 A, 436B against each other to disengage the claw 428. Stopping grips 443 A, 443B extend from the opposing sidewalls 436A, 436B under the upper portion 430. The stopping grips 443A, 443B are arranged to contact or otherwise engage with sides of the flexible locking clip 412 to adjust for different widths of solar panel modules P used with the low side attachment mechanism 420 and to ensure that the claw 428 is properly aligned with the bracket 404. In other embodiments, the stopping grips 443 A, 443B may not contact the flexible locking clip 412, and instead may just be used to ensure proper alignment of the claw 428 within the bracket 404. A stop 444 is also arranged at the upper portion 430 of the claw 428 to contact a rear wall of the solar panel module P to ensure that the claw 428 does not slide beyond the rear wall of the module P during installation.

[0282] Figs. 79A-79C show the process of mounting a solar panel module P within the low side attachment mechanism 402. As already stated, the process is similar to that involved with the low side attachment mechanism 120. The differences of the mounting process will now be described. First, the bracket 404 is secured to the mounting rail 342 using the flexible locking clip 412 and the / or the mounting legs 416. Specifically, the flexible locking clip 412 is arranged to be inserted into one of the adjacent slots 354 defined in the mounting rail 342. This allows the low side attachment mechanism 402 to be set up at different points along the mounting rail 342. This allows solar panel modules P of different sizes to be used within the system 300 while maintaining the nominal slope of the solar module P within the system 300. No matter which of the adjacent slots 354 engage with the flexible locking clip 412, the446959312.DOCXAttorney Docket No. 10089-2505754 mounting feet 416 can be secured within the clip spaces 365A, 365B of the mounting rail 342 to further secure the bracket 404.

[0283] The claw defines indent slots 438 A, 438B and indent holes 439 A, 439B that are both arranged to receive or otherwise engage with the indents 424A, 424B formed in the seat 418. Before the mounting process begins, the indents 424 A, 424B are received within the indent holes 439A, 439B. This allows the claw 428 to remain secured to the seat 418, so that it is not lost or misplaced. This is shown in Fig. 79A. The low side attachment mechanism 402 or the system 300 more generally can also be shipped to an end installer with the indents 424 A, 424B received within the indent holes 439 A, 439B. The indents 424 A, 424B are shaped and sized so that they can easily be removed from the indent holes 439 A, 439B and moved to the indent slots 438 A, 438B at the desired time. For example, the indents 424A, 424B may only extend away from the opposing sidewalls 422A, 422B of the seat 418 a small distance and they may have a relatively large radius of curvature so that with relatively little force, they can be removed from the indent holes 439 A, 439B and moved into the indent slots 438 A, 438B.

[0284] One way this can be done is by rotating the claw 428 about the indents 424A, 424B, so that it is essentially vertical, with the mounting space 434 aligned with the solar panel module P and module support surface 320A. This is represented by the arrows in Fig. 79A. A first arrow extends about a rear end of the claw 428, representing where an installer may typically contact the claw to facilitate its rotation. A second arrow extends about the indent 424A to show the axis about which the claw 428 rotates when this occurs. Then, an installer may apply a downward force against the claw 428. This can be done with the installer’s foot or with a tool. This will press the top edges of the indent holes 439A, 439B against the indents 424 A, 424B. The large radius of curvature of the indents 124 A, 124B will force the top edges of the indent holes 439 A, 439B to extend over the indents 124 A, 124B in the downward direction of the applied force. This simultaneously causes the opposing sidewalls 436A, 436B of the claw 428 to bend to allow the opposing sidewalls 436A, 436B to further slide over the indents 424A, 424B until the indents 424 A, 424B are no longer within the indent holes 439 A, 439B. The indent slots 438A, 438B are aligned with the indent holes 439A, 439B, so that when this occurs, the claw 428 will continue to slide downward until the indents 424A, 424B are received within the indent slots 438A, 438B. The downward movement of the claw 428 is represented by the arrow in Fig. 79B1. At this point, the sidewalls 436A, 436B will unflex. An installer can feel the flexing and unflexing of the sidewalls 436A, 436B to know when the indents 424A, 424B have been displaced from the indent holes 439A, 439B and received within456959312.DOCXAttorney Docket No. 10089-2505754 the indent slots 438 A, 438B. This transition is also visible to the installer. At this point an installer can stop applying the downward force on the claw 428.

[0285] An installer can also continue to apply the downward force to the claw 428 until the claw 428 is engaged with the seat 418 and solar panel module P. As the claw 428 continues to move downward, sliding over the module support surface 420A and solar panel module P, the flexible tabs 440A, 440B respectively engage with the rows of locking teeth 426A, 426B on the seat 418. The flexible tabs 440A, 440B are bent and deformable, so that they can deflect and easily move from one tooth to another in the downward direction. As the flexible tabs 440 A, 440B move in the downward direction, their contact with the teeth generates a noise that indicates the flexible tabs 440A, 440B have engaged with a new locking tooth. As the claw 428 slides over the seat 418, the tongue 414 of the bracket 404 moves into the space formed between the flexible tabs 440A, 440B and contacts sides of the flexible tabs 440A, 440B. This contact pushes the flexible locking tabs 440A, 440B in the direction of the locking teeth 426A, 426B. When the claw 428 is at its final position relative to the seat 418 and solar panel module P, the contact between the tongue 414 and the flexible tabs 440A, 440B ensures that the flexible tabs 440A, 440B remain engaged with the teeth 426A, 426B. It also helps to ensure that the claw 428 cannot be removed from the seat 418 and solar panel module P.

[0286] To disengage the flexible tabs 440A, 440B from the teeth 426A, 426B, an installer can press against the recessed surfaces 442A, 442B. This causes the sidewalls 436A, 436B to flex in a direction that disengages the flexible tabs 440A, 440B from the locking teeth 426A, 426B. Depending on the size and position of the tongue 414 relative to the flexible tabs 440A, 440B, a tool may be used to apply an adequate force to the recessed surfaces 442A, 442B to disengage the flexible tabs 440A, 440B from the locking teeth 426A, 426B. In some instances, a tool may be used to disengage the deflectable tabs 440A, 440B from the tongue 414. A tool may also be used to disengage the deflectable tabs 440A 440B from the locking teeth 426A, 426B, instead of using the recessed surface 442 A, 442B.

[0287] High Side / Tilt Arm

[0288] With reference to Figs. 80-82, parts of the high side attachment mechanism 450 will now be discussed. The process of mounting the solar panel module P to the high side attachment mechanism 450 and the features used for that process are described in U.S. Patent Application Serial No. 18 / 244,887 and International Patent Application No. PCT / US2024 / 045920. In short, the high side attachment mechanism 450 includes a tilt arm 452 connected to the mounting rail 342. At a top end of the tilt arm 452 is shaped to receive a locking piece 454. The tilt arm 452 also defines a slot 453. The slot 453 is arranged to receive466959312.DOCXAttorney Docket No. 10089-2505754 the solar panel module P therein after the module P is secured and rotated within the low side attachment mechanism 402. The locking piece 454 is designed to contact a bottom wall of the solar panel module P to secure it within the slot 453.

[0289] A difference between the tilt arm 452 and that described in the above-referenced applications is how the tilt arm 452 is secured to the mounting rail 344. Specifically, the tilt arm 452 defines extruded holes 456A, 456B that are received within high side holes 356A, 356B that are respectively formed within the sidewalls 352A, 352B of the mounting rail 342. This allows the tilt arm 452 to rotate about the axis defined by the extruded holes 456A, 456B and high side holes 356A, 356B. The tilt arm 452 includes side walls 458A, 458B and a rear wall 460 that define a space, so that the tilt arm 452 can rest on the mounting rail 342 before it is rotated upward into the mounting position. The walls 458A, 458B, 460 of the tilt arm 452 may be sized, so that they receive the mounting rail 342 in this position. This allows the tilt arm 452 to be compactly arranged with the mounting rail 342 for shipping and storage. To allow the tilt arm 452 to rotate into its mounting position, the sidewalls 458A, 458B extend a distance beyond the rear wall 460 to define a mounting space 462 therebetween. The mounting space 462 is sized to fit the mounting rail 342 within. The extruded holes 456A, 456B extend from the parts of the sidewalls 458A, 458B that define the mounting space 462.

[0290] The ends of the sidewalls 458A, 458B define engagement surfaces 466A, 466B that are aligned with the hems 355A, 355B defined in the sidewalls 352A, 352B of the mounting rail 342. The engagement surfaces 466A, 466B are arranged to contact the hems 355A, 355B, so that the tilt arm 452 is supported in the upright position by hems 355A, 355B of the mounting rail 342. The hems 355A, 355B receive the engagement surfaces 466A, 466B when the tilt arm 452 is rotated into the upright position and the hems 355A, 355B prevent the bending or flexing of the sidewalls 458A, 458B and maintain the position of the extruded holes 456A, 456B within the high side holes 356A, 356B. The tilt arm 452 defines support surfaces 467A, 467B that are formed between the sidewalls 458A, 458B and the rear wall 460. The support surfaces 467A, 467B are arranged to respectively contact the ends of the curved sections 364A, 364B of the sidewalls 352A, 352B of the mounting rail 342 to support the tilt arm 452 against the mounting rail 342 in the upright position. The sidewalls 458A, 458B also define alignment lips 468 A, 468B that are arranged to be received within the cut outs 357A, 357B defined in the sidewalls 352A, 352B of the mounting rail 342. This arrangement ensures that the tilt arm 352 is properly aligned relative to the mounting rail 342 and that the tilt arm 352 is properly secured against the mounting rail 342 for stable and compact storage and shipping.476959312.DOCXAttorney Docket No. 10089-2505754

[0291] As noted above, the mounting rails 344 are arranged to overlap with the support rail 322. This can be done in a variety of ways. Figs. 83-88 show the different arrangements possible depending on how mounting rails 344 are secured to the support rail 322. Fig. 83 shows opposing ends of adjacent mounting rails 344 secured to the support rail 322. A first mounting rail 342 has its second end 348 supported by the support rail 322. The first mounting rail 342 has high side holes 356A, 356B to secure the tilt arm 452 of the high side attachment mechanism 450 to the mounting rail 342. The second mounting rail 342’ has its first end 346’ supported by the support rail 322. The second mounting rail 342’ has adjacent slots 354’ to connect the deflecting clip 412 of the bracket 404 of the low side attachment mechanism 402. This allows for a high side attachment mechanism 450 to be arranged next to a low side attachment mechanism 402. The high side attachment mechanism 450 and the low side attachment mechanism 402 are shown connected to the respective rails 344, 344’ in Figs. 85 and 88. Fig. 84 shows to rails 344, 344’ arranged with their first ends 346, 346’ extending over the support arm 322. This allows two low side attachment mechanisms 402 to be arranged adjacent to one another. Figs. 85 and 87 show the two low side attachment mechanisms 402 adjacent to each other. Figs. 85 and 86 show two high side attachment mechanisms 450 connected adjacent to each other. Although the mounting rails 344, 344’ are not shown by themselves, one will easily appreciate what the rail arrangement would look like given the extensive description that has already been provided. Fig. 85 shows a four-panel array, with each solar panel module P being supported by a system 300. Although the solar panel modules P are arranged at different angles, it is clear that the system 300 allows for the modules P to be arranged at the same angle facing in the same direction. Other arrangements of the solar panel modules P can be had with the system 300. While the different mounting arrangements are described in connection with the system 300, system 10 has the same capabilities where low side attachment mechanisms 120 can be adjacent to one another in an array in the Y-direction and high side attachment mechanism 170 can be adjacent to one another in an array in the Y- direction.

[0292] As discussed above, the system 300 can be packaged and shipped with the low side attachment mechanism 402 and the high side attachment mechanism 450 already connected to the mounting rail 342. Examples of this are shown in Figs. 89-90B. Fig. 89 shows a mounting rail 342 with a low side connection mechanism 102 and a high side attachment mechanism 450 connected thereto. With respect to the low side attachment mechanism 402, the indents 424 A, 424B of the seat 418 are in the corresponding indent holes 439A, 439B of the claw 428, and the claw 428 is rotated downward to be partially received486959312.DOCXAttorney Docket No. 10089-2505754 between the opposing sidewalls 406A, 406B of the bracket 404. With respect to the high side attachment mechanism, the extruded holes 456A, 456B of the tilt arm 452 are in the corresponding high side mounting holes 356A, 356B of the mounting rail 342, and the tilt arm 452 is rotated downward, so that top wall 350 and parts of the sidewalls 352A, 352B of the mounting rail 342 are located within the space defined by the sidewalls 458A, 458B and rear wall 460 of the tilt arm 452. The locking piece 454 is still held within the space defined at the top of the tilt arm 452.

[0293] Fig. 90A focuses on the arrangement of overlapping mounting rails 342, 342’ at the first ends 346, 346’ when a low side attachment mechanism 402, 402’ is connected to each mounting rail 342, 342’. The dashed lines show how the features of the top mounting rail 342 and low side attachment mechanism 402 are aligned with the bottom mounting rail 342’ and low side attachment mechanism 402’. The relative sizes and shapes of the features shown allow for multiple mounting rails 342 and low side connection mechanisms 402 to be stacked on top of one another for stable and storage. Fig. 90B focuses on the arrangement of overlapping mounting rails 342, 342’at the second ends 348, 348’ when a high side attachment mechanism 450, 450’ is connected to each mounting rail 342, 342’. The dashed lines show how the features of the top mounting rail 344 and high side attachment mechanism 450 are aligned with the bottom mounting rail 342’ and high side attachment mechanism 450’. The relative sizes and shapes of the features shown allow for multiple mounting rails 342 and high side connection mechanisms 450 to be stacked on top of one another for stable and compact shipping and storage. For clarity, high side attachment mechanisms 450, 450’ have been left out of Fig. 90A, and low side attachment mechanisms 402, 402’ have been left out of Fig. 90B. When system 300 is shipped, the mounting rails 342, 342’ may have both low side attachment mechanisms 402, 402’ and high side attachment mechanisms 450, 450’ connected in their respective locations.

[0294] System 500

[0295] In Figs. 91A-109, a third solar panel module system 500 and its components are shown. Examples of these components working together to support a single solar panel module P is shown in Fig. 91A, but the system can be used to support multiple solar panel modules P within an array as shown in Fig. 91B-91C. The specifics of the system 500 and its components are discussed in greater detail below. Some features of this system 500 are similar to or the same as those of the first system 10 and second system 300.

[0296] For example, a high load assembly is used with system 500 to support an underside of the solar panel module P to provide extra support if and when snow accumulates on the496959312.DOCXAttorney Docket No. 10089-2505754 surface of the module P like the high load assembly 250 of system 10. The general structure of the features of the high load assembly of system 500 is the same as high load assembly 250 of system 10. These similar features of system 500 will not be discussed in the level of detail as they were in connection with system 10. Additionally, some of the features of system 500 are the same as or similar to those discussed in U.S. Patent Application Serial No. 18 / 244,887 and International Patent Application No. PCT / US2024 / 045920, the disclosures of which are hereby incorporated by reference in their entireties.

[0297] With reference to Fig. 91A-91C, the system includes feet 512 that are used to support the system 500 on a roof (not shown) or another support surface. The arrangement of the system 500 allows for less contact points with the roof than other systems known in the art. Rails 560 are secured to the feet 512. The rails 560 support ballast blocks 614 and provide mounting points for a low side attachment mechanism 800 and / or a high side attachment mechanism 670, which are used to secure the solar panel module P. The rails 560 may be identical and can be used for either function. The rails 560 used to mount the low side attachment mechanism 800 and the high side attachment mechanism 670 are called Y-rails and are thought of as extending in a north-south direction in a south facing array. When referring to these rails 560 specifically, they will be referred to as Y-rails 560A. The rails 560 used to support the ballast blocks are called X-rails and are thought of as extending in an east-west direction in a south facing array. When referring to these rails specifically, they will be referred to as X-rails 560B.

[0298] Foot / Pad

[0299] With reference to Figs. 92A-94, an example of a foot assembly 510 used in system 500 is shown. The foot assembly 510 includes a foot 512 and a cover 550 that is connected to the foot 512 with a fastener 546. As shown in Figs. 93A-93E, the foot 512 includes a base 513 and a body 514 extending from the base 513. The body 514 defines a top face 516, and the base 513 defines a bottom face 518. The top face 516 is used to support the rails 560, and the bottom face 518 is used to contact the roof. Extending from the base 513 a distance away from the body 514 are mounting posts 522A, 522B, 522C, 522D. The mounting posts 522A, 522B, 522C, 522D include mounting lips 524A, 524B, 524C, 524D at the respective ends thereof. The mounting lips 524A, 524B, 524C, 524D are used to secure a Y-rail 560A to the foot assembly 510. The mounting lips 524A, 524B, 524C, 524D are similar to mounting lips 24A, 24B, 24C, and 24D. Support walls 526, 528, 530, 532 extend from the base 513. A first support wall 526 and a second support wall 528 are connected to a first side of the body 514. A third support wall 530 and a fourth support wall 532 are connected to a second side of the body 514506959312.DOCXAttorney Docket No. 10089-2505754 opposite the first and second walls 526, 528. As shown, the support walls 526, 528, 530, 532 are substantially identical, but they may take other shapes around the body 514 and base 513.

[0300] Parts of the top face 516 and walls 526, 528, 530, 532 are used to support an underside of the Y-rail 560A. Specifically, the top face 516 defines a first rail support surface 534, a second rail support surface 536, a third rail support surface 538, and a fourth rail support surface 540. The rail support surfaces 534, 536, 538, 540 are arranged symmetrically on the foot 512, with the first rail support surface 534 and the second rail support surface 536 arranged on one side of the foot 512 and the third rail support surface 538 and the fourth rail support surface 540 arranged on an opposing side of the foot 512. With this arrangement, the first rail support surface 534 and the third rail support surface 538 are identical to each other, and the second rail support surface 536 and the fourth rail support surface 540 are identical to each other. The first rail support surface 534 and the third rail support surface 538 are substantially flat. The second rail support surface 536 and the fourth rail support surface 540 are sloped and extend downward from, respectively, the first rail support surface 534 and the third rail support surface 538. It is to be understood that the rail support surfaces 534, 536, 538, 540 may be arranged differently from the manner shown, so long as the rail support surfaces 534, 536, 538, 540 can still provide support for the Y-rail 560A. How the rail support surfaces 534, 536, 538, 540 and support walls 526, 528, 530, 532 support the Y-rail 560A will be described in greater detail below.

[0301] Between the first rail support surface 534 and the third rail support surface 538, the body 514 includes a central portion 535 and ramped portions 537A, 537B. Slots 547A, 547B are defined between the central portion 535 and an adjacent ramped portion 537A, 537B. The slots 547A, 547B are substantially parallel to each other and extend through each of the rail support surfaces 534, 536, 538, 540. The slots 547A, 547B divide each of the rail support surfaces 534, 536, 538, 540 into three segments. The first rail support surface 534 is divided into three segments 534A, 534B, 534C. The second rail support surface 536 is divided into three segments 536A, 536B, 536C. The third rail support surface 538 is divided into three segments 538 A, 538B, 538C. The fourth rail support surface 540 is divided into three segments 540A, 540B, 540C.

[0302] The central portion 535 has a flat top surface 535 A that extends between the second segment of the first rail support surface 534B and the second segment of the third rail support surface 538B at an elevation slightly below the tops of both segments 534B, 538B. An aperture 539 is defined within the central portion 535 to receive the fastener 546 therein. Locking lips 541A, 541B extend from opposing sides of the central portion 535. The locking lips 541A,516959312.DOCXAttorney Docket No. 10089-2505754541B extend into one of the slots 547A, 547B and are arranged to secure the cover 550, which will be described below. The first ramped portion 537A extends between the first segment of the first rail support surface 534A and the first segment of the third rail support surface 538 A. The second ramped portion 537B extends between the third segment of the first rail support surface 534C and the third segment of the third rail support surface 538C. Both ramped segments 537A, 537B slope downwards beginning at points across from the central portion 535 and ending at points at or proximate to the base 513. The ramped segments 537A, 537B may be located entirely between their respective rail support surface segments 534A, 538 A, 534C, 538C, or they may extend beyond these segments some distance.

[0303] The foot 512 also includes central wall groupings 542, 544 extending from the base513 and arranged on opposing sides of the body 514 between adjacent support walls 526, 528, 530, 532. Specifically, the first central wall grouping 542 is arranged centrally along the body514 between the first support wall 526 and the second support wall 528. The second central wall grouping 544 is arranged between the third support wall 530 and the fourth support wall 532. The first central wall grouping 542 includes a first lateral wall 542A and a second lateral wall 542B extending from the body 514 and a longitudinal wall 542C extending between opposing ends of the lateral walls 542A, 542B. The longitudinal wall 542C includes a protrusion 543. The second central wall grouping 544 has the same arrangement, with a protrusion 545 provided on its longitudinal wall 544C. The protrusions 543 interact with a base 674 that is used in connection with the high side attachment 670 and low side attachment 800, which will be described in greater detail below.

[0304] The foot assembly 510 also includes a cover 550 that engages with the body 514 of the foot 512. As shown in Fig. 94, cover 550 has a hub 552 with connectors 553 A, 553B, 553C, 553D and arms 554A, 554B extending outward from the hub 552. The hub 552 is substantially flat and is arranged to rest on top of the central portion 535 of the body 514. The hub 552 defines an aperture 555 that is to be aligned with aperture 539 in the central portion 535. The connectors 553A, 553B, 553C, 553D extend from the hub 552 and connect the arms 554A, 554B to the hub 552. As shown, first and second connectors 553A, 553B extend between the hub 552 and the first arm 554A, and third and fourth connectors 553C, 553D extend between the hub 552 and the second arm 554B. Gaps 556A, 556B are defined by the cover 550 between respective connectors 553A, 553B, 553C, 553D and arms 554A, 554B. The connectors 553A, 553B, 553C, 553D and arms 554A, 554B are shaped, so that the arms 554A, 554B can be arranged within the slots 547A, 547B of body 514. Specifically, the connectors 553 A, 553B, 553C, 553D are curved, so that they extend downward from the hub 552 and partially into the526959312.DOCXAttorney Docket No. 10089-2505754 slots 548 A, 548B. As the arms 554 A, 554B enter the slots 547 A, 547B, the locking lips 549 A, 549B deflect inward to allow the arms 554 A, 554B to move into the slots 547 A, 547B. After the arms 554A, 554B move beyond the locking lips 541A, 541B, the lips 541A, 541B move back to their original position, where they are arranged within the gaps 556A, 556B. In this position, the locking lips 541A, 541B may contact a surface of the arms 554A, 554B and prevent the arms 554A, 554B from being removed from slots 548A, 548B. When the cover 550 is arranged in this position, with the arms 554A, 554B in the slots 547A, 547B and the locking lips 541 A, 541B within the gaps 556A, 556B, the fastener 546 may be inserted into the aligned apertures 555, 539 to secure the cover 550 to the foot 512. Apertures 555, 539 and fastener 546 may be threaded such that the threads of apertures 555, 539 are configured to cooperate with the threads of fastener 546, providing a secure mechanical connection to the foot 512. The fastener 546 and apertures 555,539 may be shaped, so that tools are not needed to secure the fastener 546 within the apertures 555, 539. In one embodiment, the fastener 546 may formed integrally with the cover 550 as opposed to being a separate part of the foot assembly 510. Cover 550 is configured to prevent fastener 546 from disconnecting from foot 512. Cover 550 is made of stronger material than foot 512. For example, cover 550 can be made of stamped steel while foot 512 is made of plastic.

[0305] The foot assemblies 510 allow for more effective load distribution within the system 500. For example, the foot 512 is shaped to distribute weight from the system 500 over a surface area, such that fewer foot assemblies 510 are needed in the system 500 compared to others known in the art. This results in fewer points of contact between the system 500 and the mounting surface on which it is arranged, such as a roof. The foot assemblies 510 may be arranged in specific ways to provide adequate support for the system 500 as well. For example, a first foot assembly 510 may be placed next to a second foot assembly 510 so that both with the same rail 560 at or proximate to a specific load bearing point. Each load bearing point may have multiple foot assemblies 510 to help with load distribution. Foot assemblies 510 may also help with load distribution by being placed under an X-rail 560B. X-rails 560B are used in connection with a ballast system, so providing foot assemblies 510 at advantageous positions with respect to the ballast system helps to further distribute a load through the system 500. Foot assemblies 510 may also be used by the system 500 to assist in holding a high load assembly configured to assist in holding snow. Foot assemblies 510 may be used for multiple functions and / or purposes within the same system 500.

[0306] Rails536959312.DOCXAttorney Docket No. 10089-2505754

[0307] With reference to Figs. 95A-96B, a rail 560 that may be interchangeably used as a Y-rail 560A or an X-rail 560B is shown. Rail 560 may have a similar or same structure as rail 60. Examples of this structure includes an elongated body 562 extending between two ends 564, 566. Fig. 95B shows a first end 564 of the rail 560, and Fig. 95C shows a second end 566 of the rail 560. One will understand that the body 562 extends between the two ends 564, 566. A first side flange 568 and a second side flange 570 extend from opposing sides of the elongated body 562. As shown, the elongated body 562 generally takes the shape of an upside down U, defining a top wall 571 and side walls 574A, 574B. The side flanges 568, 570 extend from ends of the respective side walls 574A, 574B. Slots 572A, 572B are defined within the side walls 574A, 574B. The rail 560 defines an aperture 573 and slot 563 in the top wall 571. The rail 560 as shown also has secondary apertures 575. It is understood that secondary apertures 575 may be replaced such that top wall 571 has multiple apertures 573.

[0308] With reference to Figs. 96A-96B, a rail 560 is shown arranged on a foot assembly 510. The mounting lips 524A, 524B, 524C, 524D extend from their respective mounting posts 522A, 522B, 522C, 522D to engage with flanges 568, 570 of the rail 560. As shown, mounting lips 524B, 524C are arranged to engage the second flange 568 and mounting lips 524A, 524D are arranged to engage the first flange 570. The mounting lips 524A, 524B, 524C, 524D extend over a respective rail support surface 534, 536, 538, 540 to define a mounting space. The mounting space is sized to accommodate the side flanges 568, 570 of at least two rails 560. In some instances, the mounting lips 524A, 524B, 524C, 524D may contact and / or dig into the side flanges 568, 570 to further facilitate the connection between the rail 560 and the foot assembly 510. In other instances, the mounting lips 524A, 524B, 524C, 524D may only define a mounting space, which essentially serve as receiving slots for the flanges 568, 570, allowing the rail 560 to be secured to the foot assembly 510 via a snap fit. Aperture 573 in the top wall 571 is aligned with the aperture 539 to receive fastener 546 which may further secure the rail 560 to the foot assembly 510.

[0309] Notably, the foot 512 is shaped to be complementary to the underside of the rail 560. Specifically, the side flanges 568, 570 rest on support walls 526, 528, 530, 532 and central wall groupings 542, 544. The side walls 574A, 574B, respectively, rest on the second rail support surface 536 and the fourth rail support surface 540. The top wall 571 rests on the first rail support surface 534, the third rail support surface 538, and cover 550. Additionally, the aperture 573 in top wall 571 is configured to align with fastener 546, such that fastener 546 may extend through aperture 573 while the rest of top wall 571 rests on first rail support surface 534, the third rail support surface 538, and central portion 535.546959312.DOCXAttorney Docket No. 10089-2505754

[0310] Secondary apertures 575 are also configured to align with fastener 546 to engage additional foot assemblies 510. In some instances, secondary aperture 575 engage with a foot assembly 510 to help with load distribution. In some instances, secondary apertures 575 engage with a foot assembly 510 to connect a first rail 560 and a second rail 560’ such that a first end 564 of rail 560 is in contact with a second end 566’ of rail 560’. Fastener 546 extends through aperture 573 of the first end 564 of rail 560 and also secondary aperture 575’ of the second end 566’ of rail 560’. Additionally, the side flanges 568, 570 of rail 560 and the side flanges 568’, 570’ of rail 570’ both are received within the mounting space by mounting lips 524A, 524B, 524C, 524D. In this way, the rails 560, 560’ are secured to each other and the foot assembly 510.

[0311] Ballast Rail Support Clip & Ballast Arrangement

[0312] With reference to Figs. 97A-100D, a ballast system and its relevant features are shown. The ballast system uses two X-rails 560B, 560B’ to support ballast blocks 614 therebetween. The X-rails 560B, 560B’ are arranged on adjacent Y-rails 560A. Fig. 97A-97B shows a ballast rail support clip 600 that is secured to a Y-rail 560A to be used in securing one or more X-rails 560B, 560B’. Fig. 98 shows a base 674 that is also secured to a Y-rail 560A and is also used in securing one of the X-rails 560B. As shown in Fig. 99-100D the first X-rail 650B is secured to a Y-rail 560A by the base 674 and a ballast clip 600. The second X-rail 650B’ is secured to a Y-rail 560A by two ballast clips 600. In this arrangement, three ballast clips 600 and one base 674 are used to support adjacent X-rails 650B, 650B’. In other arrangements, four ballast clips 600 may be used to secure both X-rails 650B, 650B’, with the fourth ballast clip 600 replacing the base 674 in the arrangement previously described.

[0313] The ballast rail support clip 600 has a body 602 that has a central portion 604 and wings 612 extending from opposing sides of the body 602. The wings 612 extend perpendicularly upward from the body 602 in a first perpendicular section 625, then parallel to the body 602 in a parallel section 627, and then perpendicularly downward in regards to the body 602 in a second perpendicular section 617. With this arrangement, when the support clip 600 is placed over a Y-rail 560A, the second perpendicular section 617 of wings 612 extend alongside side walls 574A, 574B. Hooks 611 extend from the second perpendicular sections 617 of wing 612. Hooks 611 curl under their respective wings 612 and terminate with retaining teeth 623 to dig into a bottom of the flanges 568, 570 of Y-rail 560A. The second perpendicular sections 617 and hooks 611 are flexible to allow the ballast rail support clip 600 to engage and disengage with Y-rail 560A. The support clip 600 may have a snap-fit with the Y-rail 560A.556959312.DOCXAttorney Docket No. 10089-2505754The hooks 611 and teeth 623 prevent displacement of support clip 600 in a direction perpendicular to the longitudinal axis of Y-rail 560A.

[0314] A lip 609 extends from central portion 604 and is configured to extend into a slot 563 defined in the Y-rail 560A. This further secures the ballast support clip 600 to the Y-rail 560A in a desired location and prevents the clip 600 from being displaced along the Y-rail 560A. Slots 563 may be formed in the Y-rail 560A at specific locations, which ensures that the ballast support clips 600 are spaced apart at appropriate distances to secure an X-rail 560B, 560B’ therebetween.

[0315] The first perpendicular sections 625 both have a first securing tooth 621. A first gap 619 is defined in the first perpendicular sections 635 between first securing tooth 621 and body 604. First securing tooth 621 is slanted such that first securing tooth 621 is thickest next to first gap 619, at a point closest to the body 604. The second perpendicular sections 617 both have a second securing tooth 613. A second gap 615 exists between second securing tooth 613 and a portion of second perpendicular section 617. Second securing tooth 613 is slanted such that second securing tooth 613 is thickest next to second gap 615. First gap 619 and second gap 615 are aligned, such that an elevated portion of the side flanges 568, 570 of X-rail 560B may be slid under first securing tooth 621 and second securing tooth 613 and be held in place within the first gap 619 and second gap 615. The first securing tooth 621 and the second securing tooth 613 may be arranged to dig into the side flanges 568, 570 of an X-rail 560B to secure the X-rail 560B to the ballast rail support clip 600 on top of the Y-rail 560A to which the ballast support clip 600 is connected. In this way, the top section of Y-rail 560A and securing teeth 621, 613 hold X-rail 560B in place against the Y-rail 560A in a direction perpendicular to the longitudinal axis of Y-rail 560A. The first teeth 621 may act to constrain the flanges within the gaps 619 and 615. The second teeth 613 may penetrate a top surface of the flanges 568, 570 of the X-rail 560B and exert a clamping force securing the flanges 568, 570 of the X-rail 560B to the Y-rail 560 A.

[0316] The parallel sections 627 of the wings 612 include two rear clips 610. Rear clips 610 extend from wings 612 at a slight angle and fold back over themselves to create a narrow U-shape. With this arrangement, a wind deflector 724 can be secured to the ballast support clip 610 within the U-shape formed by the rear clips 610. The wind deflector 724 will be described in greater detail below. The rear clips 610 terminate with an additional securing mechanism 626. The additional securing mechanism 626 extends from rear clips 610 at an angle. A portion of additional securing mechanism 626 extends to the side and then in the direction of the looped section of rear clips 610.566959312.DOCXAttorney Docket No. 10089-2505754

[0317] FIG. 98 shows the base 674. The base 674 includes a bottom section 676, designed to fit over a top surface of a Y-rail 560A, and a mounting section 680, designed to secure part of the low side attachment mechanism 800 and / or high side attachment 670, which will be discussed in greater detail below. The bottom section 676 includes a central portion 685 and wings 682 that extend outward from the central portion 685. The central portion 685 and wings 682 are shaped to fit over the elongated body 562 and side flanges 568, 570 of the Y-rail 560A. Specifically, the central portion 685 may rest on the top wall 571 of the Y-rail 560A, and the wings 682 may rest on the side walls 574A, 574B. The wings 682 may also rest on or over the side flanges 568, 570.

[0318] The central portion 685 defines an aperture 710 through which the fastener 546 extends. The wings are folded over themselves, so that a receiving space 683 is defined within the wings 682. The receiving space 683 is shaped, so that the clip 576 can fit within the base 674. At one end, the wings 682 define recesses 686, which are configured to receive a side flange 568, 570 of an X-rail 560B used in the ballast support system. Holding fingers 687 extend inward from outer ends of the wings 682 and extend over the side flange 568, 570 of an X-rail 560B. The holding fingers 687 may contact the side flange 568, 570, or they may be received within slots or openings formed in the side flange 568, 570 to further secure the rail 560B.

[0319] Locking tabs 711 extend from the wings 682 away from the receiving spaces 683 and the central portion 685. The locking tabs 711 each define openings 712 and include a deflected segment 713 that extends partially within their respective openings 712, so that it can engage with one of the protrusions 543 of a foot assembly 510. Specifically, locking tabs 711 are configured to deflect over the protrusions 543 when force is placed on base 674 in a direction towards foot assembly 510. As the locking tabs 711 deflect, the protrusions 543 are received within the openings 712 such that locking tab 711 snaps back into its natural configuration with each protrusion 543 fully received within its respective opening 712. The deflected segment 713 is arranged, so that it contacts its respective protrusion 543 further securing the locking tabs 711 in place against the protrusions 543. The contact between the deflected segments 713 and protrusions 543 create a wedge effect that helps to secure the base 674 to a foot assembly 510.

[0320] With reference to Figs. 99-100D the installation process of a ballast block is shown. Fig. 99 shows two ballast blocks 614 arranged on adjacent X-rails 560B, 560B’ within system 500. The first X-rail 560B is secured between a base 674 and a ballast rail support clip 600. The second X-rail 560B’ is secured between two ballast rail support clips 600. As shown in576959312.DOCXAttorney Docket No. 10089-2505754FIG. 100A, Y-rail 560A is secured to two foot assemblies 510. As shown in FIG. 100B, a base 674 is secured onto Y-rail 560A. The base 674 attaches to the Y-rail 560A in the manner described above. The first X-rail 560B is moved toward base 674 so that the first side flange 568 is received within the recesses 686. The second X-rail 560B’ is placed at a distance from the first X-rail 560B, such that the distance between the X-rails 560B, 560B’ is equal to the length or width of a ballast block 614. The resulting configuration is shown in FIG. 100C. Then, ballast rail support clips 600, 600’ are secured on the Y-rail 560A as discussed above. After being secured to the Y-rail 560A, ballast rail support clip 600 is moved toward the X-rail 560B until the locking flanges 621, 613 of ballast rail support clip 600 extend over the second side flange 570 of X-rail 560B and gaps 619, 615 receive an elevated portion of the second side flange 570. The same process is repeated with ballast rail support clip 600’ and X-rail 560B’ . After ballast rail support clips 600, 600’ are moved into position to secure X-rails 560B, 560B’, a portion of the clips 609, 609’ are received within the slots 563 defined in the Y-rail 560A to secure the ballast rail support clips 600, 600’ in place relative to the Y-rail 560A and base 674. The final, secured positions of ballast rail support clips 600, 600’ are shown in FIG. 100D. Finally, the ballast blocks 614 are placed between the X-rails 560B, 560B’ such that opposing sides of a ballast block 614 rest on the adjacent X-rail 560B, 560B’. Specifically, a first side of the ballast block 614 rests on the second side flange 570 of the first X-rail 560B, and a second side of the ballast block 614 rests on the first side flange 568 of the second X-rail 560B’. In this instance, the ballast block 614 prevents lateral movement of the second X-rail 560B’ toward the first X-rail 560B. The single support clip 600’ located on the opposing side of the second X-rail 560B’ prevents lateral movement of the second X-rail 560B’ away from the first X-rail 560B.

[0321] Alternatively, in some embodiments, the first side flange 568’ of the second X-rail 560B’ is secured by an additional ballast rail support clip 600’ as follows. A first ballast rail support clip 600 is placed onto Y-rail 560A as described above, with the clip 609 received inside of slot 563. The second X-rail 560B’ is moved toward the support clip 600 so that the second side flange 570 is moved under locking flanges 621, 613 and an elevated portion of the first side flange 568 is received within gaps 619, 615. Then, a second ballast rail support clip 600 is secured on the Y-rail 560A and moved toward the first side flange 568 of the X-rail 560B until the locking flanges 621, 613 extend over the first side flange 568 of the X-rail 560B and gaps 619, 615 receive an elevated portion of the second side flange 570. At this position, the clip 609 can be received within the slot 563 defined in the Y-rail 560A. In examples where three ballast rail support clips 600 are used to secure adjacent X-rails 560B, 560B’, the process586959312.DOCXAttorney Docket No. 10089-2505754 described in this paragraph can be repeated for the first X-rail 560B while the second X-rail 560B’ is secured as described in the previous paragraph. In examples where four ballast rail support clips 600 are used to secure adjacent X-rails 560B, 560B’, the process described in this paragraph can be repeated for both X-rails 560B, 560B’ resulting in a similar support arrangement for the ballast blocks 614.High Side Attachment Mechanism

[0322] With reference to Figs. 98 and 101-105, the base 674, clip 576, and high side connection mechanism 670 will now be described. The base 674 and clip 576 can also be used with the low side attachment mechanism 800, which is described in greater detail below.

[0323] Referring back to FIG. 98, the mounting section 680 of the base 674 is designed to secure the tilt arm 678. The mounting section includes support segments 688 that extend from a portion of the wings 682. The support segments 688 include a sloped portion 691 extending in a direction upward and over its respective wing 682, and a straight portion 692 extending vertically from their respective sloped portions centrally located above each wing 683. The support segments 688 are configured to receive the tilt arm 678 therebetween, such that one side of tilt arm 678 rests against each straight portion 692 of support segment 688. Mounting section 680 also includes fastening apertures 689 formed in the vertical portions thereof. Fastening aperture 689 may align with connecting aperture 690 of tilt arm 678. A fastener may be inserted through fastening aperture 689 and connecting aperture 690 such that tilt arm 678 and base 674 are connected. The fastener may be a bolt and nut, one or two rivets, or any other suitable fastener. In some embodiments, the tilt arm 678 may include protrusions in place of the connecting apertures 690. In this example, the protrusions are received within the fastening apertures 689 of the support segments 688.

[0324] FIG. 101 shows the clip 576. The clip 576 is arranged to be held within the base 674. The clip 576 includes a top portion 585 that is configured to rest on top of the central portion 685 of the base 674. The top portion 585 defines a through hole 578. The through hole 578 has a first portion 580 and a second portion 582. The first portion 580 is configured to be aligned with aperture 710 of the base 674 to receive the fastener 546 therethrough. The second portion 582 is also configured to receive the fastener 546 as the clip 576 moves during the mounting process. The second portion 582 is surrounded by elevated portions 584. This is described below in connection with both attachment mechanisms. The top portion 585 also defines elongated slots 579 arranged on opposing sides of the through hole 578. Different features of the high and low side attachment mechanisms are configured to be received within the elongated slots 579 to move the clip 576 during the mounting processes. Sliding surfaces596959312.DOCXAttorney Docket No. 10089-2505754581 extend from opposing sides of the top portion 585. The sliding surfaces 581 are configured to fit within the receiving spaces 683 defined by the wings 682. The sliding surfaces 581 can also be arranged to lay flat against and slide along interior surfaces of the wings 682. Alignment tabs 583 are formed on a side of the sliding surfaces 581. The alignment tabs 583 are arranged to be aligned with both the first indicator aperture 679 and the second indicator aperture 681. Before mounting, the alignment tabs 583 may be visible through the first indicator aperture 679. After mounting, the alignment tabs 583 may be visible through the second indicator aperture 681.

[0325] Figs. 102A-105 show the high side attachment mechanism 670. High side attachment mechanism 670 includes the base 674, tilt arm 678, and locking piece 718. High side attachment mechanism 670 is secured to the rail 560 and panel P without the use of tools.

[0326] For the high side attachment mechanism 670, the tilt arm 678 is received between the support segments 688, such that one side of tilt arm 678 rests against each support segment 688. Mounting section 680 also includes fastening apertures 689 formed in the vertical portions thereof. Fastening aperture 689 may align with connecting aperture 690 of tilt arm 678. A fastener may be inserted through fastening aperture 689 and connecting aperture 690 such that tilt arm 678 and base 674 are connected. The fastener may be a bolt and nut, rivets, or any other suitable fastener. In some embodiments, the tilt arm 678 may include protrusions in place of the connecting apertures 690. In this example, the protrusions are received within the fastening apertures 689 of the support segments 688.

[0327] Fig. 103 shows the tilt arm 678. In addition to the connecting apertures 690, the tilt arm 678 includes ramps 684 at a first end thereof, which may be used to hold the tilt arm 678 in place as described below. The tilt arm 678 includes a recess 716. Wings 717 extend from the body of tilt arm 678 to define the recess 716. Wings 717 have a first gap 723 between the upper side of wings 717 and the body of the tilt arm 678. First gap 723 and recess 716 are configured to receive the solar panel module P therein as well as a locking piece 718. Wings 717 include an aperture 719 so that locking piece 718 may be secured to tilt arm 678. The locking piece 718, shown in Fig. 104, is substantially similar to that described in United States Patent Application No. 18 / 244,887, which is hereby incorporated in its entirety, so the majority of its features will not be described herein. The locking piece 718 includes retaining portion 740, retaining teeth 742, rounded portion 744, locking teeth 746, and folded portion 748, which may be configured to hold an edge of the panel. The retaining teeth 742 may create an electrical bond between the solar panel module P and the system 500.606959312.DOCXAttorney Docket No. 10089-2505754

[0328] Tilt arm 678 also has slots 722, configured to receive hooks from bracket 720, such that bracket 720 may be attached to tilt arm 678 to be used with a wind deflector as described below. Tilt arm 678 also has deflectable clip 725. Deflectable clip 725 is configured to be received by one of recesses 734 of the bracket 720, such that an outwardly extending portion of delectable clip 725 is received in recesses 734.

[0329] The tilt arm 678 is installed by first connecting the tilt arm 678 to the base 674 as described above. Then, the base 674 is secured to the Y-rail 560A and foot assembly 510 by aligning the fastener 546 with the aperture 710 of the base 674 and the first portion 580 of the through hole 578 of the clip 576. Then, the base 674 is pressed downward over the Y-rail 560A and foot assembly 510, so that the fastener 546 is received through the apertures 710, 578 and the locking tabs 711 engage with the protrusions 543 as discussed above. FIG. 105 shows an exploded view of the foot assembly 510, base 674, and clip 576 in alignment to show how the fastener 546 extends through the apertures 710, 578.

[0330] The tilt arm 678 is then rotated upwards until it is locked into place relative to the base 674. This is done by way of ramps 684 located at the end of the tilt arm 678. As the tilt arm 678 is rotated upwards, the ramps 684 are received within the elongated slots 579 of the clip 576. As the tilt arm 678 continues to rotate, surfaces of the ramps 684 contact the clip 576 and move the clip relative to the fastener 546. This causes the fastener 546 to transition from the first portion 580 of the through hole 578 to the second portion 582. When fastener 546 transitions to second portion 582, elevated portions 584 slide underneath a portion of the head of fastener 546. As a result, the head of the fastener 546 pushes clip 576 toward Y-rail 560A and foot assembly 510. Elevated portions 584 are sized so that when tilt arm 678 has been rotated into a locked position, a part of the elevated portions 584 that rests directly below fastener 546 extends from base 674 to fastener 546. In this way, clip 576 and base 674 may not move in a direction parallel to the longitudinal axis of fastener 546 when the tilt arm 678 is in a locked position. Both the size of the second portion 582 relative to the fastener 546 and the height of the elevated portions 584 relative to the space between the fastener 546 and the base 674 creates a friction fit between the clip 574 and the fastener 546, which creates resistance as the tilt arm 678 is further rotated into its locked position. The end of the second portion 582 of the through hole 578 acts as a stop for the tilt arm 678 and secures it in place in its mounting position. This allows an installer to move the solar panel module P into the recess 716 where it can be locked in place by the locking piece 718.

[0331] Moving tilt arm 678 back into a parallel position acts as a release lever for panel P.

[0332] Low Side Attachment Mechanism616959312.DOCXAttorney Docket No. 10089-2505754

[0333] With reference to FIGS. 106-107B, relevant features of the low side attachment mechanism 800 for use in system 500 are shown. The claw used in the low side attachment mechanism 800 is the same as claw 154 shown and described in connection with FIGS. 24, 25, and 29. This claw will be identified with the same reference characters as claw 154. The low side attachment mechanism 800 allows for the rotational mounting of a solar panel module P similar to the low side attachment mechanisms 120, 402 previously described in connection with systems 10, 300.

[0334] The low side attachment mechanism 800 includes a seat 802 to support the solar panel module P and the claw 154 to secure the solar panel module P to the seat 802. The seat 802 is configured to be secured to the base 674 at a desired location along the Y-rail 560A. The seat 802 includes opposing mounting sections 804A, 804B that support the solar panel module P and secure the seat 802 to the base 674. The seat 802 also includes a claw support section 806 extending between and connecting the mounting sections 804 A, 804B. Each of the mounting sections 804A, 804B include respective top walls 808A, 808B, mounting wings 810A, 810B, and module support tabs 812A, 812B. The mounting wings 810A, 810B and module support tabs 812A, 812B extend from outer sides of their respective top wall 808A, 808B. As shown, the mounting wings 810A, 810B extend from a side of the top walls 808A, 808B that extends in the Y-direction (parallel to Y-rails 560A), and the module support tabs 812A, 812B extend from a side of the top walls 808A, 808B that extends in the X-direction (parallel to X-rails 560B). The top walls 808A, 808B are arranged to support a solar panel module P during the mounting process.

[0335] The mounting wings 810A, 810B define seat apertures 814A, 814B, which defines a rotation axis for the seat 802 and claw 154. The mounted wings 810A, 810B terminate with a shaped tip 816A, 816B. The shaped tips 816A, 816B define a contact surface 818A, 818B that will engage with the clip 576 as described below. Additional apertures (shown but not numbered) may be formed in the mounting wings 810A, 810B to reduce the amount of materials used or to provide some flexibility. The mounting wings 810A, 810B make take shapes other than those shown in the figures, so long as the seat 802 functions as described below.

[0336] The module support tabs 812A, 812B include a support portion 820A, 820B that extends in a direction opposite that of the mounting wings 810A, 810B. The support portions 820 A, 820B are offset inwardly from their respective mounting wings 810A, 810B. The support portions 820A, 820B define respective support surfaces 822A, 822B that are arranged to support a solar panel module P during the mounting process.626959312.DOCXAttorney Docket No. 10089-2505754

[0337] The claw support section 806 includes sidewalls 824A, 824B, a claw wall 826, and a deflecting tab 828. The sidewalls 824A, 824B extend away from a side of the top walls 808A, 808B that is opposite from the mounting wings 810A, 81 OB. The sidewalls 824A, 824B extend in the same direction as the mounting wings 810A, 810. The claw wall 826 extends between and connects the sidewalls 824A, 824B and is substantially parallel to the top walls 808A, 808B. The deflecting tab 828 extends from an end of the claw wall 826. The deflecting tab 828 is angled downward, in a direction that extends partly away from the sidewalls 824A, 824B.

[0338] The seat 802 is mounted to the base 674 by aligning the seat apertures 814A, 814B with the fastening apertures 689. Fasteners (not shown) may extend through the aligned apertures 814, 689, to rotatably secure the seat 802 to the base 674. In other examples, the base 674 may have features, such as posts, that extend from the support segments 688 in place of the fasteners. These features may be received within the seat apertures 814A, 814B to allow the seat 802 to rotate relative to the base 674. When the seat 802 is mounted to the base 674, the shaped tips 816A, 816B extend into the elongated slots 579.

[0339] To mount the low side attachment mechanism 800 and a solar panel module P, the seat 802 is first connected to the base 674. The base 674 is then aligned with the fastener 546 of the foot assembly 510. Then, the base 674 is pressed downward over the Y-rail 560A and foot assembly 510, so that the fastener 546 is received through the apertures 710, 578 and the locking tabs 711 engage with the protrusions 543 as discussed above. The module P is then arranged relative to the mounted base 674 and seat 802, so that it can be directed downward and onto the support surfaces 822 A, 822B. A first side of the module P rests on the support surfaces 822A, 822B, such that a second, bottom side contacts, or is arranged very close to, the top walls 808 A, 808B of the seat 802. The claw 154 may be then moved over the top walls 808A, 808B and the bottom flange of the solar panel module P, so that the top walls 808A, 808B and bottom side of the module P are received within the mounting space 162 formed between the upper portion 156 and lower portion 158 of the claw 154. As this occurs, the locking teeth 160 may slide over and engage with the deflecting tab 828 formed in the claw wall 826 of the seat 802. The engagement between the teeth 160 and deflecting tab 828 may secure the claw 154 to the seat 134. The strength and resiliency of the teeth 160 and deflecting tab 828, and the claw 154 and seat 802 more generally, may be such that outside forces, such as weather, cannot disengage the teeth 160 from the deflecting tab 828.

[0340] After the claw 154 has been secured to the seat 802 and solar panel module P, the claw 154, seat 802, and module P can be rotated within the base 674 into their mounting position. This is done in the same manner as the low side attachment mechanisms 120, 402636959312.DOCXAttorney Docket No. 10089-2505754 discussed above. As the module P rotates, the bottom wall may contact a top edge surface of the support segments 688 of the base 674. This may create an electrical bond between the solar panel module P and the system 500. This may support the solar panel module P in its mounting position, where the opposite end of the module P can be received within the recess 716 defined in the tilt arm 678 of the high side attachment mechanism 670, where it can be locked in place by the locking piece 718.

[0341] As this rotation occurs, the shaped tips 816A, 816B move within the elongated slots 579 of the clip 576. This causes the contact surfaces 818A, 818B to contact the parts of the clip 576 that define the elongated slots 579. This moves the clip 576 relative to the fastener 546. As the clip 576 moves in the Y direction, the fastener transitions from the first portion 580 of the through hole 578 to the second portion 582. When fastener 546 transitions to second portion 582, elevated portions 584 slide underneath a portion of the head of fastener 546. As a result, the head of the fastener 546 pushes clip 576 toward Y-rail 560A and foot assembly 510. Elevated portions 584 are sized so that when the seat 802 has been rotated into a locked position, a part of the elevated portions 584 that rests directly below fastener 546 extends from base 674 to fastener 546. In this way, clip 576 and base 674 may not move in a direction parallel to the longitudinal axis of fastener 546 when the seat 802 is in a locked position. Both the size of the second portion 582 relative to the fastener 546 and the height of the elevated portions 584 relative to the space between the fastener 546 and the base 674 creates a friction fit between the clip 574 and the fastener 546, which creates resistance as the seat 802 is further rotated into its locked position. This entire mounting process may occur without the need for tools or other installation aids.Wind Deflector

[0342] With reference to Figs. 108-109, an embodiment of part of a wind deflector assembly 719 is shown. Wind deflector assembly 719 may be the same or similar structure as wind deflector assembly 219, 233. Wind deflector assembly 719 can be secured to a back end, also known as a north end of the system 500 and any north sides of rows of panels as needed. Wind deflector assembly 719 uses part of tilt arm 678 to connect to the Y-rail 560A and / or foot assembly 510.

[0343] Specifically, a bracket 720 has hooks 728 configured to be inserted into the slots 722 of the tilt arm 678. Hooks 728 contain recesses 730 and extension portions 732 such that extension portions 732 are inserted into the slots 722 and then hooks 728 is slid upward so the edges of the slots 722 are contained in the recesses 730. The extension portions 732 prevent bracket 720 from moving in a direction perpendicular to the longitudinal axis of tilt arm 678.646959312.DOCXAttorney Docket No. 10089-2505754The bracket 720 also has recesses 734, configured to receive an outwardly extending portion of a deflectable clip 725. Upon sliding hooks 728 upward, the deflectable clip 725 snaps back into place and the outwardly extending portion extends into recesses 734. The outwardly extending portion is configured such that deflectable clip 725 cannot be moved in a direction parallel to the longitudinal axis of tilt arm 678 without applying force to deflect the deflectable clip 725.

[0344] Bracket 720 is substantially L-shaped with four hooks 728 on both sides of the L- shape so that bracket 720 is adjustable. Bracket 720 holds the wind deflector 724 closer to tilt arm 678 when hooks 728 on the longer side of the L-shape connect bracket 720 to tilt arm 678. Contrarily, wind deflector 724 extends out further when hooks 728 on the shorter side of the L-shape connect bracket 720 to tilt arm 678. In this way, bracket 720 may be adjusted based on the space between the rows in order to provide an installer more walking space.

[0345] Both sides of the L-shape of bracket 720 terminate with a curved clip 726 that is used to mount wind deflectors 724 thereto. Wind deflectors 724 include a body 735 that extends between a first end 736 and a second end 738. The first end 736 defines a number of slots (not numbered) that receive a curved clip 726 to secure the wind deflector 724 to a mounting point. Curved clip 726 is configured such that the clip opening faces upward. As a result, the bottom of curved clip 726 holds the first end 736 of wind deflector up. The second end 738 includes flange 739, which is shaped to be received within the rear clip 610. Flange 739 is extended into rear clip 610. Additional securing mechanism 626 secures the flange 739 within rear clip 610 as additional securing mechanism 626 is angled downward, so additional securing mechanism 626 may contact and / or dig into the flange 739 to secure second end 738 in place.

[0346] While specific embodiments of the device of the present disclosure have been described in detail, it will be appreciated by those skilled in the art that various modifications and alternatives to those details could be developed in light of the overall teachings of the disclosure. Accordingly, the particular arrangements disclosed are meant to be illustrative only and not limiting as to the scope of the device of the present disclosure which is to be given the full breadth of the claims appended and any and all equivalents thereof. It is also to be understood that any combination of the different features disclosed in the different embodiments of this disclosure may be combined in another embodiment and are not outside of the scope of this disclosure.656959312.DOCX

Claims

Attorney Docket No. 10089-2505754CLAIMS1. A solar panel module mounting system comprising: a foot assembly for securing a rail to a mounting surface, the foot assembly comprising a foot defining a top face and a bottom face, at least a portion of the bottom face is configured to contact the mounting surface; a rail configured to be supported on the foot assembly, the rail comprising: an elongated body; a first side flange extending from a first side of the elongated body; and a second side flange extending from a second side of the elongated body, opposite the first side; a base configured to be secured to the foot assembly, the base being configured to connect with at least one attachment mechanism on which a solar panel module is mounted, wherein at least a portion of the top face defines a support surface configured to support an underside of the elongated body of the rail, wherein the foot comprises at least one protrusion, wherein the base comprises at least one attachment tab, and wherein the at least one attachment tab is configured to engage with the at least one protrusion when the base is arranged on top of the rail.

2. The solar panel module mounting system of claim 1, wherein the foot comprises: a body defining the top face; and a plurality of mounting lips comprising at least one first mounting lip arranged on a first side of the body and at least one second mounting lip arranged on a second side of the body opposite the first side, wherein the plurality of mounting lips are configured to secure the longitudinal rail to the foot.

3. The solar panel module mounting system of claim 2, wherein the at least one first mounting lip is configured to engage with the first side flange, and wherein the at least one second mounting lip is configured to engage with the second side flange.666959312.D0CXAttorney Docket No. 10089-25057544. The solar panel module mounting system of claim 3, wherein the at least one first mounting lip comprises a first pair of mounting lips and wherein the at least one second mounting lip comprises a second pair of mounting lips.

5. The solar panel module mounting system of claim 4, wherein the at least one attachment tab comprises two attachment tabs, and wherein the at least one protrusion comprises two protrusions, a first protrusion arranged between the first pair of mounting lips and a second protrusion arranged between the second pair of mounting lips.

6. The solar panel module mounting system of claim 2, wherein the foot assembly further comprises a fastener, and wherein the longitudinal rail defines a rail aperture to receive the fastener therethrough when the rail is supported on the foot assembly.

7. The solar panel module mounting system of claim 6, wherein the base defines a base aperture configured to receive the fastener therethrough when the base is secured to the foot assembly.

8. The solar panel module mounting system of claim 7 further comprising a clip arranged within the base, the clip comprising: a through hole configured to receive the fastener therethrough; a first elongated aperture arranged on a first side of the through hole; and a second elongated aperture arranged on a second side of the through hole, opposite the first side.

9. The solar panel module mounting system of claim 8, wherein the first elongated aperture and the second elongated aperture are configured to receive a portion of the at least one attachment mechanism therein, when the at least one attachment mechanism is connected to the base.676959312.D0CXAttorney Docket No. 10089-250575410. The solar panel module mounting system of claim 9, wherein the through hole has a first portion and a second portion, the first portion having a larger diameter than a width of the second portion and the second portion being elongated.

11. The solar panel module mounting system of claim 9, wherein the portion of the at least one attachment mechanism is configured to move the clip such that the fastener transitions from a first portion of the through hole to a second portion of the through hole when the attachment mechanism is transitioned from a first portion to a second position in relation to the rail.

12. The solar panel module mounting system of claim 11, wherein the second portion of the through hole is flanked by elevated areas.

13. The solar panel mounting system of claim 1, wherein the base comprises a pair of corresponding apertures configured to align with corresponding features of the at least one attachment mechanism.

14. The solar panel mounting system of claim 1, wherein the at least one attachment mechanism is one of a low side attachment mechanism and a high side attachment mechanism.

15. A solar panel module mounting system comprising: a plurality of foot assemblies for securing at least one rail to a mounting surface, the plurality of foot assemblies each comprise a foot defining a top face and a bottom face, at least a portion of the bottom faces being configured to contact the mounting surface; at least one rail configured to be supported on the plurality of foot assemblies, the at least one rail comprising: an elongated body; a first side flange extending from a first side of the elongated body; and a second side flange extending from a second side of the elongated body, opposite the first side; a plurality of bases comprising: a first base secured to a first end of the longitudinal rail; and a second base secured to a second end of the longitudinal rail;686959312.DOCXAttorney Docket No. 10089-2505754 a low side attachment mechanism secured to the first base and configured to rotatably mount a first end of the solar panel module; a high side attachment mechanism secured to the second base and defining a slot configured to receive a second end of the solar panel module therein; wherein at least a portion of the top face defines a support surface configured to support an underside of the elongated body of the at least one rail, wherein the foot comprises at least one protrusion, wherein the plurality of bases comprise at least one attachment tab, and wherein the at least one attachment tab is configured to engage with the at least one protrusion when the base is arranged on top of the at least one rail.

16. The solar panel module mounting system of claim 15, wherein the plurality of foot assemblies each comprise a fastener, wherein the at least one rail defines a plurality of apertures each configured to receive one of the fasteners of the plurality of foot assemblies therethrough, and wherein the plurality of bases each define a base aperture configured to receive one of the fasteners of the plurality of foot assemblies therethrough.

17. The solar panel module mounting system of claim 16 further comprising a plurality of clips, the plurality of clips comprising: a first clip arranged within the first base; and a second clip arranged within the second base, wherein the plurality of clips each comprise: a through hole configured to receive one of the fasteners of the plurality of foot assemblies therethrough; a first elongated aperture arranged on a first side of the through hole; and a second elongated aperture arranged on a second side of the through hole, opposite the first side.

18. The solar panel module mounting system of claim 17, wherein the first elongated aperture and the second elongated aperture of the first clip are configured to receive a portion of the low side attachment mechanism therein, and696959312.D0CXAttorney Docket No. 10089-2505754 wherein the portion of the low side attachment mechanism is configured to move the first clip such that the fastener received within the through hole, transitions from a first portion of the through hole to a second portion of the through hole.

19. The solar panel module mounting system of claim 17, wherein the first elongated aperture and the second elongated aperture of the second clip are configured to receive a portion of the high side attachment mechanism therein, and wherein the portion of the high side attachment mechanism is configured to move the second clip such that the fastener received within the through hole, transitions from a first portion of the through hole to a second portion of the through hole.

20. The solar panel module mounting system of claim 15, wherein each one of the plurality of bases comprises a pair of corresponding apertures.

21. The solar panel module mounting system of claim 15, wherein the pair of corresponding apertures of the first base are configured to align with a pair of corresponding apertures of the low side connection mechanism, and wherein the low side attachment mechanism is configured to rotate about an axis defined by the corresponding apertures of the first base.

22. The solar panel mounting system of claim 15, wherein the pair of corresponding apertures of the second base are configured to receive portions of the high side attachment mechanism therein, such that the high side mechanism is configured to rotate about the pair of corresponding apertures of the second base.706959312.DOCX

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