Hybrid solar panel mounting assembly

• US 10,594,250 B2
• Filed: 04/25/2016
• Issued: 03/17/2020
• Est. Priority Date: 08/03/2015
• Status: Active Grant

• Current Assignee: Unirac Incorporated
• Original Assignee: Unirac Incorporated
• Inventors: Schuit, Nathan, Mayfield, Jason, Cowen, December, Womacks, Darren
• Primary Examiner(s): Cajilig, Christine T
• Application Number:
  US15/138,030
• Publication Number:
  US 20170040928A1
• Time in Patent Office: 1,422 Days
• CPC Class Codes: F24S 2025/801 having hollow parts with closed cross-section
• CPC Class Codes: F24S 25/35 by means of profiles with a cross-section defining separate supporting portions for adjacent modules
• CPC Class Codes: F24S 25/632 Side connectors; Base connectors
• CPC Class Codes: F24S 25/636 clamping by screw-threaded elements
• CPC Class Codes: F24S 25/65 for coupling adjacent supporting elements, e.g. for connecting profiles together
• CPC Class Codes: F24S 25/67 for coupling adjacent modules or their peripheral frames for fixing modules or their peripheral frames to supporting elements F24S25/63
• CPC Class Codes: H02S 20/23 specially adapted for roof structures
• CPC Class Codes: Y02B 10/10 Photovoltaic [PV]
• CPC Class Codes: Y02B 10/20 Solar thermal
• CPC Class Codes: Y02E 10/47 Mountings or tracking
• CPC Class Codes: Y02E 10/50 Photovoltaic [PV] energy

Abstract

An apparatus and method for mounting a solar panel array on a surface is disclosed. The solar panel array includes a plurality of solar panel modules and a hybrid solar panel module mounting assembly. The hybrid solar panel module mounting assembly includes a component of a rail-based mounting system and a component of a rail-less mounting system. At least one of the plurality of solar panel modules is mounted on the component of the rail-based mounting system and at least one of the plurality of solar panel modules is mounted on the component of the rail-less mounting system.

Claims

1. A hybrid solar module mounting assembly for mounting a plurality of solar modules in a solar array, the assembly comprising:

a trim-rail of a rail-based mounting system, the trim-rail including a continuous structural rail that extends across at least two spaced-apart attachments on a roof; and

a bracket of a rail-less mounting system,

wherein;

the trim-rail and the bracket are interchangeable,

the trim-rail;

is disposed at an outer-most edge of the solar array,

extends an entire length or width of at least one solar module of the plurality of solar modules, and

includes a lower ledge and an upper ledge on only one side of the trim-rail, the lower ledge and the upper ledge mounting the at least one solar module on only the one side of the trim-rail, and

the bracket extends a portion of a length or width of at least a first solar module or a discrete portion of a length or width of at least a second solar module of the plurality of solar modules of the solar array.

2. The assembly according to claim 1, wherein the bracket is disposed within an outer periphery of the solar array.

3. The assembly according to claim 1, wherein the trim-rail is a monolithic structure including a structural rail portion combined with a non-structural trim portion.

4. The assembly array according to claim 1, wherein the trim-rail is a dual track rail or a triple track rail or a low profile rail or a shared rail.

5. The assembly according to claim 1, wherein the bracket is a micro-rail or a short micro-rail.

6. The assembly according to claim 1, wherein at most two solar modules of the plurality of solar modules are mounted on the bracket.

7. The assembly according to claim 1, wherein four solar modules of the plurality of solar modules are mounted on the bracket.

8. The assembly according to claim 1, further comprising a trim mounted on the plurality of solar modules.

9. The assembly according to claim 1, wherein the bracket includes a helical vertical drive having a freestanding helical drive element and is vertically adjustable by rotating the freestanding helical drive element.

10. The assembly of claim 1, wherein the bracket is mounted on a base, wherein the bracket has a length L and the base has a width W, and wherein L/W is greater than 10 and less than 15.

11. The assembly of claim 1, wherein the bracket includes an elongated slot,

wherein a tower is transversely positionable within the elongated slot and along a length of the elongated slot,

wherein the length of the elongated slot is at least two times a width of the tower, and

wherein the elongated slot is closed along its four sides.

12. The assembly of claim 1, wherein the bracket is a floating splice that is not connected to a roof and that floats above said roof.

21. The assembly according to claim 3, wherein the trim-rail includes a track.

22. The assembly according to claim 3, wherein the trim-rail has a generally curved surface that extends downwardly and outwardly from a top of the trim-rail to a lower portion of the trim-rail and then downwardly to a lowest portion of the trim-rail.

23. The assembly according to claim 3, wherein the trim-rail has an upper vertical wall that extends from a bottom of the trim-rail, wherein the first ledge and the second ledge extend perpendicularly from the upper vertical wall, and wherein the first ledge extends further outwardly from the upper vertical wall than the second ledge.

24. The assembly according to claim 23, wherein the trim-rail defines a hollow chamber bounded by the trim portion, a lower vertical wall, and a bottom wall.

25. The assembly according to claim 24, wherein a flange extends from the lower vertical wall.

13. A method for mounting a plurality of modules in a solar array that includes a hybrid solar module mounting assembly including a trim-rail of a rail-based mounting system and a bracket of a rail-less mounting system, the trim-rail having a continuous structural rail that extends across at least two spaced-apart attachments on a roof, the method comprising steps of:

mounting, on a surface, the hybrid solar module mounting assembly;

mounting at least one of the plurality of solar modules on the trim-rail such that the trim-rail is disposed at an outer-most edge of the solar array, extends an entire length or width of at least one solar module of the plurality of solar modules on only one side of the trim-rail;

mounting at least one of the plurality of solar modules on the bracket; and

interchanging the trim-rail and the bracket.

14. The method according to claim 13, wherein the trim-rail is disposed at an outer-most edge of the entire solar array, and the bracket is disposed within an outer periphery of the solar array.

15. The method according to claim 13, wherein the trim-rail is a monolithic structure including a structural rail portion combined with a non-structural trim portion.

16. The method according to claim 13, wherein the trim-rail is a dual track rail or a triple track rail or a low profile rail or a shared rail.

17. The method according to claim 13, wherein the bracket is a micro-rail or a short micro-rail.

18. The method according to claim 13, wherein at most two solar modules of the plurality of solar modules are mounted on the bracket.

19. The method according to claim 13, wherein four solar modules of the plurality of solar modules are mounted on the bracket.

20. The method according to claim 13, further comprising the step of mounting a trim on the plurality of solar modules.