# US 12,771,285 B2 · Module mounting system for a solar structure

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- Number: US 12,771,285 B2
- Document ID: US12771285B2
- Status: Granted
- Kind: B2
- Application number: 18/825,506
- Filed: 2024-09-05
- Published: 2025-03-06
- Granted: 2026-10-20
- Earliest claimed: 2023-09-05
- Assignees: FLEXRACK by Qcells LLC
- Applicants: FLEXRACK by Qcells LLC
- Inventors: Gregory P. Huzyak; Nathan A. Knapp; Dalton L. Hancock; Jesse J. Saluga
- Web page: https://patentgrep.com/patent/US12771285B2

## CPC

- H02S 20/32: specially adapted for solar tracking
- H02S: GENERATION OF ELECTRIC POWER BY CONVERSION OF INFRARED RADIATION, VISIBLE LIGHT OR ULTRAVIOLET LIGHT, e.g. USING PHOTOVOLTAIC [PV] MODULES (obtaining electrical energy from radioactive sources G21H1/12; light sensitive inorganic semiconductor devices H10F; light sensitive organic semiconductor devices H10K30/00; thermoelectric devices H10N10/00; pyroelectric devices H10N15/00)

## Abstract

A module mounting assembly for coupling a solar module to a torque tube comprises a hat rail; a first vertical member pivotably coupled to the hat rail at first connection points and capable of being pivoted to rest flush on a first torque tube side surface during installation, the first vertical member having first retention features; a second vertical member pivotably coupled to the hat rail at second connection points and capable of being pivoted to rest flush on a second torque tube side surface during installation, the second vertical member having second retention features; a locking mechanism configured to cooperate with the first retention features and the second retention features to prevent the first and second vertical members from pivoting to secure the first vertical member flush on the first torque tube side surface and to secure the second vertical member flush on the second torque tube side surface.

## Claims

### Claim 1

A module mounting assembly for coupling a solar module to a torque tube, the torque tube having a top tube surface, a first side tube surface, a second side tube surface opposing the first side tube surface, and a bottom tube surface, the module mounting assembly comprising:
a hat rail having a top rail surface, a bottom rail opening, opposing side rail surfaces, first connection points and second connection points;
a first vertical member pivotably attached to the hat rail at the first connection points, the first vertical member capable of being pivoted inward about a first axis defined by the first connection points through the bottom rail opening to at least partially reside within a first internal portion of the hat rail, the first vertical member capable of being pivoted outward to rest flush on the first tube side surface of the torque tube during installation, the first vertical member having one or more first retention features;
a second vertical member pivotably attached to the hat rail at the second connection points, the second vertical member capable of being pivoted inward about a second axis defined by the second connection points through the bottom rail opening to at least partially reside within a second internal portion of the hat rail, the second vertical member capable of being pivoted outward to rest flush on the second tube side surface of the torque tube during installation, the second vertical member having one or more second retention features;
a locking mechanism configured to cooperate with the one or more first retention features and the one or more second retention features to secure the first vertical member against the first tube side surface of the torque tube and the second vertical member flush against the second tube side surface of the torque tube.

### Claim 2 (depends on 1)

The module mounting assembly of claim 1, wherein the hat rail includes an omega beam.

### Claim 3 (depends on 1)

The module mounting assembly of claim 1, wherein the first connection points are disposed on the opposing side rail surfaces at a first position along a length of the hat rail.

### Claim 4 (depends on 3)

The module mounting assembly of claim 3, wherein the second connection points are disposed on the opposing side rail surfaces at a second position along a length of the hat rail.

### Claim 5 (depends on 4)

The module mounting assembly of claim 4, wherein a distance between the first position and the second position is equal to a width between the first side tube surface and the second side tube surface.

### Claim 6 (depends on 5)

The module mounting assembly of claim 5, wherein the first connection points and the second connection points include rail holes.

### Claim 7 (depends on 6)

The module mounting assembly of claim 6, wherein the first vertical member is pivotably coupled to the hat rail at the first connection points using a coupling bolt and coupling nut.

### Claim 8 (depends on 1)

The module mounting assembly of claim 1, wherein the first vertical member includes a flat surface configured to rest flush against the first tube side surface of the torque tube after installation.

### Claim 9 (depends on 1)

The module mounting assembly of claim 1, wherein the first vertical member includes side extensions to increase rigidity of the first vertical member.

### Claim 10 (depends on 9)

The module mounting assembly of claim 9, wherein the side extensions includes a top segment with coupling holes configured to cooperate with the hat rail at the first connection points.

### Claim 11 (depends on 10)

The module mounting assembly of claim 10, wherein the first vertical member includes a consistent width.

### Claim 12 (depends on 10)

The module mounting assembly of claim 10, wherein the first vertical member has a strut-coupling segment that is wider than the top segment, and further comprising a supporting strut that is coupled to the strut-coupling segment and to the hat rail at third connection points.

### Claim 13 (depends on 1)

The module mounting assembly of claim 1, wherein the one or more first retention features of the first vertical member include a notch and retention tabs.

### Claim 14 (depends on 1)

The module mounting assembly of claim 1, wherein the one or more second retention features of the second vertical member include a window.

### Claim 15 (depends on 1)

The module mounting assembly of claim 1, wherein the locking mechanism includes a locking bolt and a locking nut.

### Claim 16 (depends on 15)

The module mounting assembly of claim 15, wherein the locking bolt is sufficiently long to couple the first vertical member and the second vertical member across the bottom tube surface of the torque tube.

### Claim 17

A method for coupling a module mounting assembly to a torque tube, the torque tube having a top tube surface, a first side tube surface, a second side tube surface opposing the first side tube surface, and a bottom tube surface, the method comprising:
positioning a hat rail on top of a torque tube, the hat rail having a top rail surface, a bottom rail opening, opposing side rail surfaces, first connection points and second connection points;
pivotably attaching a first vertical member to the hat rail at the first connection points, the first vertical member having one or more first retention features;
pivotably attaching a second vertical member to the hat rail at the second connection points, the second vertical member having one or more second retention features;
pivoting the first vertical member outward about a first axis defined by the first connection points from a first internal portion of the hat rail to rest flush on the first tube side surface of the torque tube;
pivoting the second vertical member outward about a second axis defined by the second connection points from a second internal portion of the hat rail to rest flush on the second tube side surface of the torque tube; and
installing a locking mechanism to cooperate with the one or more first retention features and the one or more second retention features to secure the first vertical member against the first tube side surface of the torque tube and the second vertical member flush against the second tube side surface of the torque tube.

### Claim 18 (depends on 17)

The method of claim 17, wherein the first vertical member has a strut-coupling segment that is wider than the top segment, and further comprising coupling a supporting strut to the strut-coupling segment and to the hat rail at third connection points.

### Claim 19 (depends on 17)

The method of claim 17, wherein the one or more first retention features of the first vertical member include a notch and retention tabs.

### Claim 20 (depends on 17)

The method of claim 17, wherein the one or more second retention features of the second vertical member include a window.

### Claim 21 (depends on 17)

The method of claim 17, wherein the locking mechanism includes a locking bolt and a locking nut.