Hybrid solar panel mounting assembly with a tilted ledge
View Patent ↗A trim-rail for use in a solar panel mounting assembly is disclosed. The trim-rail includes a tilted spring support ledge on a side of the trim-rail. A photovoltaic module is elastically supportable on the tilted spring support ledge when the photovoltaic module is installed on the tilted spring support ledge.
1. A trim-rail for use in a solar panel mounting assembly, comprising:
a first vertical wall;
a horizontal wall intersecting with the first vertical wall;
a second vertical wall intersecting with the horizontal wall and extending downwardly from the horizontal wall, the second vertical wall having a free end that terminates a distance apart from the horizontal wall, and the second vertical wall being spaced apart from the first vertical wall such that a gap exists therebetween, the gap sized to receive a portion of a footer;
a proximal support portion extending horizontally from the free end of the second vertical wall in a direction away from the gap; and
a tilted spring support ledge integrally joined to, and cantilevered from, the proximal support portion,
wherein a photovoltaic module is elastically supportable on the tilted spring support ledge when the photovoltaic module is installed on the tilted spring support ledge.
2. The trim-rail of claim 1 , wherein the tilted spring support ledge is tilted at an angle ranging from 10-30 degrees to a horizontal plane when the photovoltaic module is not mounted on the tilted spring support ledge.
3. The trim-rail of claim 1 , wherein the tilted spring support ledge is tilted at an angle of approximately 20 degrees to a horizontal plane when the photovoltaic module is not mounted on the tilted spring support ledge.
4. The trim-rail of claim 1 , wherein the tilted spring support ledge includes a tilted portion and a horizontal distal portion.
5. The trim-rail of claim 1 , wherein a thickness of the proximal support portion is at least 3 times greater than a thickness of the tilted spring support ledge.
6. The trim-rail of claim 1 , wherein the tilted spring support ledge has a width (W) and a thickness (t) sufficient to provide an elastic, spring-like force that pushes upward on a photovoltaic module when the photovoltaic module is installed on the tilted spring support ledge so as to minimize a gap between an upper bracket of the trim-rail and the photovoltaic module.
7. The trim-rail of claim 6 , wherein a ratio of the width to the thickness (W/t) is greater than or equal to 10.
8. The trim-rail of claim 6 , wherein a ratio of the width to the thickness (W/t) is greater than or equal to 15.
9. A solar panel mounting assembly, comprising:
a trim-rail including:
a first vertical wall,
a horizontal wall intersecting with the first vertical wall,
a second vertical wall intersecting with the horizontal wall and extending downwardly from the horizontal wall, the second vertical wall having a free end that terminates a distance apart from the horizontal wall, and the second vertical wall being spaced apart from the first vertical wall such that a gap exists therebetween, the gap sized to receive a portion of a footer,
a proximal support portion extending horizontally from the free end of the second vertical wall in a direction away from the gap, and
a tilted spring support ledge integrally joined to, and cantilevered from, the proximal support portion, and
a slot defined by the tilted spring support ledge on a lower side of the slot, the second vertical wall on a middle portion of the slot, and a wing on an upper side of the slot.
10. The solar panel mounting assembly of claim 9 , wherein the tilted spring support ledge is tilted at an angle ranging from 10-30 degrees to a horizontal plane when the photovoltaic module is not supported on the tilted spring support ledge.
11. The solar panel mounting assembly of claim 9 , wherein the tilted spring support ledge is tilted at an angle of approximately 20 degrees to a horizontal plane when the photovoltaic module is not supported on the tilted spring support ledge.
12. The solar panel mounting assembly of claim 9 , wherein the tilted spring support ledge includes a tilted portion and a horizontal distal portion.
13. The solar panel mounting assembly of claim 9 , further comprising a photovoltaic module configured to be mounted in the slot upon installation of the solar panel mounting assembly.
14. The solar panel mounting assembly of claim 13 , wherein the tilted spring support ledge is deflected when the photovoltaic module is installed in the slot, and
wherein the deflected tilted spring support ledge provides a vertical force that pushes upward on the installed photovoltaic module so as to minimize a gap between the wing and the photovoltaic module.
15. The solar panel mounting assembly of claim 9 , wherein the tilted spring support ledge has a width (W) and a thickness (t) and wherein a ratio of the width to the thickness (W/t) is greater than or equal to 10.
16. The solar panel mounting assembly of claim 9 , wherein the tilted spring support ledge has a width (W) and a thickness (t) and wherein a ratio of the width to the thickness (W/t) is greater than or equal to 15.
17. The solar panel mounting assembly of claim 9 , further comprising:
a footer assembly including the footer, the footer being configured to be clamped in the gap by a tri-drive nut when installed; and
a base track configured to be clamped to the footer assembly when installed.
18. The solar panel mounting assembly of claim 17 , further comprising a photovoltaic module configured to be is mounted in the slot upon installation of the solar panel mounting assembly.
19. A method of mounting a photovoltaic module in a trim-rail, the trim-rail including:
a vertical wall intersecting with, and extending downwardly from, a horizontal wall, the vertical wall having a free end terminating a distance apart from the horizontal wall
a proximal support portion extending from, and transversely to, the free end of the vertical wall,
a tilted spring support ledge integrally joined to, and cantilevered from, the proximal support portion, a thickness of the proximal support portion being greater than a thickness of the tilted spring support ledge, and
a slot defined by the tilted spring support ledge on a lower side of the slot, the vertical wall on a middle portion of the slot, and a wing on an upper side of the slot;
the method comprising steps of:
inserting the photovoltaic module into the slot at an angle with respect to a horizontal plane; and
rotating the photovoltaic module back to the horizontal plane and deflecting the tilted spring support ledge by the photovoltaic module,
wherein the deflecting generates a vertical upward force on the photovoltaic module by the tilted spring support ledge so as to minimize a gap between the wing and the photovoltaic module.