Photovoltaic module mounting assembly

• US 9,306,490 B2
• Filed: 12/02/2014
• Issued: 04/05/2016
• Est. Priority Date: 08/13/2012
• Status: Active Grant

• Current Assignee: RMH Tech LLC
• Original Assignee: Dustin M.M. Haddock, Robert M.M. Haddock
• Inventors: Haddock, Dustin M. M., Haddock, Robert M. M.
• Primary Examiner(s): MATTEI, BRIAN DAVID
• Application Number:
  US14/558,356
• Publication Number:
  US 20150318817A1
• Time in Patent Office: 490 Days
• Field of Search: 521/733, 521/261, 521265-1267, 522/63, 524/66, 524/68, 524/751, 248/72, 248/228.1, 248/228.3, 248/228.5, 248/201, 248/229.12, 248/229.14, 248/229.22, 248/229.24, 248/230.3, 248/230.5, 248/231.21, 248/231.41, 248/231.61, 136/244, 136/251
• US Class Current: 1/1
• CPC Class Codes: F16B 2/065 using screw-thread elements F16B2/08 - F16B2/12 take precedence
• CPC Class Codes: F16B 2/12 using sliding jaws
• CPC Class Codes: F16B 2005/0678 in abutting relationship
• CPC Class Codes: F16B 5/0607 joining sheets or plates to each other F16B5/0692, F16B21/082 take precedence
• CPC Class Codes: F24S 2025/6008 by using toothed elements
• CPC Class Codes: F24S 25/615 for fixing to protruding parts of buildings, e.g. to corrugations or to standing seams
• CPC Class Codes: F24S 25/632 Side connectors; Base connectors
• CPC Class Codes: F24S 25/636 clamping by screw-threaded elements
• CPC Class Codes: H02S 20/22 specially adapted for buildings
• 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

A photovoltaic module mounting assembly (200) uses a mounting device (74), mounting plate (110′), lower bracket (210), upper bracket (230), and stud (114). The mounting plate (110′) is positioned on the mounting device (74), and a leg (212) of the lower bracket (210) is positioned on the mounting plate (110′). An outside surface (222) of another leg (220) of the lower bracket (210) includes teeth (224) and engages an inside surface (238) of a leg (236) of the upper bracket (230), which also has teeth (240). The mounting plate (110′) engages a lower surface (63) of a photovoltaic module (58), an end of the leg (212) of the lower bracket (210) may engage a side surface (64) of the module (58), and a head (246) on an end of another leg (232) of the upper bracket (230) may engage an upper surface (65) of the module (58).

Claims

1. A photovoltaic module mounting assembly, comprising:

a lower bracket comprising first and second legs, wherein said first leg extends in a first dimension, and wherein said second leg extends away from said first leg in a second dimension; and

an upper bracket comprising third and fourth legs, wherein said third leg of said upper bracket and said first leg of said lower bracket are spaced from one another in said second dimension and with said third leg of said upper bracket being disposed in overlying relation to said first leg of said lower bracket, wherein said fourth leg of said upper bracket extends away from said third leg of said upper bracket in a direction in which said first leg of said lower bracket is spaced from said third leg of said upper bracket, wherein said fourth leg of said upper bracket engages said second leg of said lower bracket, and wherein said second leg of said lower bracket extends away from said first leg of said lower bracket in a direction in which said third leg of said upper bracket is spaced from said first leg of said lower bracket;

a threaded clamp fastener that extends through said third leg of said upper bracket, through an open space between said third leg of said upper bracket and said first leg of said lower bracket, and through said first leg of said lower bracket, wherein said second leg of said lower bracket is located between said threaded clamp fastener and said fourth leg of said upper bracket in said first dimension, wherein a first mating surface of said second leg of said lower bracket comprises a plurality of spaced teeth and projects toward said fourth leg of said upper bracket, wherein a second mating surface of said fourth leg of said upper bracket comprises a plurality of spaced teeth and projects toward said second leg of said lower bracket, and wherein said first and second mating surfaces are disposed in interlocking relation to restrict relative motion between said upper bracket and said lower bracket in said second dimension;

a first configuration where;

     1) said third leg of said upper bracket and said first leg of said lower bracket are spaced by a first distance; and

     2) said first and second mating surfaces are disposed in a first degree of said interlocking relation to restrict relative motion between said upper bracket and said lower bracket in said second dimension;

a second configuration where;

     1) said third leg of said upper bracket and said first leg of said lower bracket are spaced by a second distance that is greater than said first distance; and

     2) said first and second mating surfaces are disposed in a second degree of said interlocking relation to restrict relative motion between said upper bracket and said lower bracket in said second dimension, wherein said first degree of said interlocking relation for said first configuration is greater than said second degree of said interlocking relation for said second configuration;

a first nut mounted on said threaded clamp fastener, engaged with said third leg of said upper bracket, and positioned outside of said open space between said first leg of said lower bracket and said third leg of said upper bracket; and

a second nut mounted on said threaded clamp fastener, engaged with said first leg of said lower bracket, and positioned within said open space between said first leg of said lower bracket and said third leg of said upper bracket.

2. The mounting assembly of claim 1, wherein an included angle between said first and second legs of said lower bracket is about 90°

.

3. The mounting assembly of claim 1, wherein said first leg of said lower bracket and said third leg of said upper bracket are at least substantially parallel to one another.

4. The mounting assembly of claim 1, wherein said lower bracket and said upper bracket collectively define a single, continuous pocket for receiving an edge portion of a photovoltaic module.

5. The mounting assembly of claim 4, wherein a height of said pocket is adjustable by changing a position of said upper bracket relative to said lower bracket which changes a spacing between said first leg and said third leg in said second dimension, wherein changing said height of said pocket changes an amount of an interlocking interface between said first and second mating surfaces that restricts relative motion between said upper bracket and said lower bracket in said second dimension.

6. The mounting assembly of claim 1, wherein a length dimension of each of said lower bracket and said upper bracket extends along an edge portion of a photovoltaic module when engaged by said mounting assembly, and wherein said lower bracket has a larger said length dimension than said upper bracket.

7. The mounting assembly of claim 1, wherein a free end of said first leg of said lower bracket comprises a raised lip that extends in a direction of an overlying portion of said upper bracket.

8. A photovoltaic system comprising the mounting assembly of claim 1 and a photovoltaic module, wherein a free end of said first leg of said lower bracket engages a side surface of said photovoltaic module.

9. The mounting assembly of claim 1, wherein said lower bracket and said upper bracket collectively define a single, continuous pocket for receiving an edge portion of a photovoltaic module, wherein said threaded clamp fastener extends through said pocket and said threaded clamp fastener, with said second nut being positioned on said threaded clamp fastener, is the only structure of said mounting assembly that is located within said pocket.

10. The mounting assembly of claim 1, wherein an included angle between said third and fourth legs of said upper bracket is about 90°

.

11. The mounting assembly of claim 1, wherein said upper bracket further comprises a head that offset from said third leg of said upper bracket in said second dimension.

12. The mounting assembly of claim 11, wherein said head is disposed at a higher elevation than said third leg of said upper bracket.

13. The mounting assembly of claim 11, wherein a free end of said head and said a free end of said first leg of said lower bracket are offset in said first dimension.

14. The mounting assembly of claim 11, wherein a free end of said head is positioned further from said threaded clamp fastener in said first dimension than a free end of said first leg of said lower bracket.

15. The mounting assembly of claim 11, wherein a transition section extends between said third leg of said upper bracket and said head, wherein said transition section of said upper bracket and a free end of said first leg of said lower bracket are at least generally aligned in said second dimension.

16. The mounting assembly of claim 11, wherein a transition section extends between said third leg of said upper bracket and said head to dispose said head at a higher elevation than said third leg of said upper bracket, wherein a free end of said head is positioned further from said threaded clamp fastener in said first dimension than a free end of said first leg of said lower bracket, and wherein said transition section of said upper bracket and a free end of said first leg of said lower bracket are at least generally aligned in said second dimension.

17. The mounting assembly of claim 16, wherein said free end of said first leg of said lower bracket comprises a raised lip that extends in a direction of an overlying portion of said upper bracket.

18. A photovoltaic system comprising the mounting assembly of claim 17 and a photovoltaic module, wherein said free end of said first leg of said lower bracket engages a side surface of said photovoltaic module.

19. The mounting assembly of claim 16, wherein a length dimension of each of said lower bracket and said upper bracket extends along an edge portion of a photovoltaic module when engaged by said mounting assembly, and wherein said lower bracket has a larger said length dimension than said upper bracket.