System For Mounting And Supporting Photovoltaic Modules

A method of securing a frame rail of a photovoltaic (PV) module support structure, comprising:

• providing a mounting element having a frame rail support portion and having a slot defined within a surface of the frame rail support portion;
• arranging first and second retaining members within the slot of the mounting element such that a frame rail engaging end of each one of the first and second retaining members is disposed on one side of the frame rail support portion and a fastening end of each one of the first and second retaining members is disposed on the other side of the frame rail support portion;
• inserting an elongated member through a plurality of openings defined within the fastening end of each of the first and second retaining members, such that a head of the elongated member engages the fastening and of first retaining member and a threaded portion of the elongated member threadedly engages a threaded surface of the fastening end of the second retaining member;
• positioning a base portion of a frame rail adjacent to the frame rail support portion of the mounting element and between the frame rail engaging ends of the first and second retaining members;
• and
• rotating the elongated member about a longitudinal axis thereof such that the threaded portion of the elongated member advances along the threaded surface of the fastening end of the second retaining member, thereby relatively moving the first retaining member in a direction toward the second retaining member so as to clamp the base portion of the frame rail between the respective frame rail engaging ends.

A system for supporting a photovoltaic (PV) module, comprising:

• a frame rail having a face that is formed so as to define a longitudinally extending channel, the longitudinally extending channel being open to the face, and the frame rail having a base that is opposite the face, a width of the base being greater than a width of the face;
• a mounting element having a frame rail support portion and having a slot defined within a surface of the frame rail support portion;
• an elongated member having a generally cylindrical body extending along a longitudinal axis between first and second opposite ends thereof, the elongated member having a head at the first end and having a threaded portion at the second end;
• and
• first and second retaining members each having a frame rail engaging end and a fastening end;
• wherein, in an assembled condition, the first and second retaining members extend through the slot of the mounting element such that the respective frame rail engaging ends are disposed on one side of the frame rail support portion and the respective fastening ends are disposed on the other side of the frame rail support portion, the frame rail engaging ends being spaced-apart and facing one another for receiving therebetwcen the base of the frame rail, the elongated member extending through a plurality of openings defined within the fastening end of each of the first and second retaining members, the head of the elongated member engaging the first retaining member and the threaded portion of the elongated member threadedly engaging the second retaining member, such that a rotational movement of the elongated member about the longitudinal axis thereof is converted into a linear movement of the second engaging member relative to the first engaging member.

A method of forming a frame rail for supporting a photovoltaic (PV) module, comprising:

• providing a sheet metal blank having opposite side edges;
• bending the sheet metal blank so as to form a closed profile, the closed profile including:
• a mounting face that is formed with a longitudinally extending channel opening to the mounting face;
• a base surface that includes a portion of the sheet metal blank adjacent to each of the opposite side edges thereof;
• and
• opposite sidewalls extending between the mounting face and the base surface,
• wherein the channel is formed to define:
• a channel base;
• opposite channel sidewalls extending away from the channel base;
• and
• two flanges extending one each away from a respective one of the opposite channel sidewalls, the metal that forms each one of the two flanges defining a retaining surface facing toward the channel base and being bent back upon itself thereby forming an edge along each one of the two flanges, the edge along each one of the two flanges joining a respective one of the retaining surfaces and the mounting face of the frame rail, the retaining surface of each flange including a lip adjacent to the edge of the respective flange, the lip being shaped for engaging a mating surface of a mounting clip;
• and
• joining together the opposite side edges of the sheet metal blank along a seam within the base surface, the seam extending along the longitudinal direction of the frame rail and being other than a welded seam.

A system for mounting a photovoltaic (PV) module, comprising:

• a frame rail having a face and being formed with a longitudinally extending channel that is open at the face, the channel having a base, opposite channel sidewalls extending away from the base, and two flanges, each one of the two flanges extending away from a respective one of the opposite channel sidewalls, the metal that forms each one of the two flanges defining a retaining surface facing toward the base of the channel and being bent back upon itself thereby forming an edge along each one of the two flanges, the edge along each one of the two flanges joining a respective one of the retaining surfaces and the face of the profile rail, the retaining surface of each flange including a lip adjacent to the edge of the respective flange for engaging a mating surface of a mounting clip;
• a fastener having an engaging and;
• a module clamp carried at an end of the fastener that is opposite the engaging end;
• and
• a mounting clip having a support end and having a retaining end, the retaining end comprising a pair of pendent legs extending away from the support end, each one of the pair of pendent legs having a mating surface that is shaped for engaging the lip adjacent to the edge of one of the flanges of the frame rail, the support end having an opening defined therethrough for receiving the engaging end of the fastener;
• wherein, in an assembled condition, the retaining end of the mounting clip is disposed within the longitudinally extending channel of the frame rail and the fastener interconnects the module clamp and the mounting clip, and
• wherein an edge portion of the PV module is retained between the support end of the mounting clip and the module clamp.

A method of mounting photovoltaic (PV) modules to a frame rail of a PV module support structure, comprising:

• providing a frame rail having a face and being formed with a longitudinally extending channel that is open at the face, the channel having a base, opposite channel sidewalls extending away from the base, and two flanges extending one each away from a respective one of the opposite channel sidewalls, the metal that forms each one of the two flanges defining a retaining surface facing toward the base of the channel and being bent back upon itself thereby forming an edge along each one of the two flanges, the edge along each one of the two flanges joining a respective one of the retaining surfaces and the face of the frame rail, the retaining surface of each flange including a lip adjacent to the edge of the respective flange, the lip being shaped for engaging a mating surface of a mounting clip;
• providing a mounting clip comprising a support end and having a retaining end, the retaining end comprising a pair of pendent legs extending away from the support end, each one of the pair of pendent legs having a mating surface that is shaped for engaging the lip adjacent to the edge of one of the flanges of the frame rail, the support end having an opening defined therethrough for receiving a threaded end of a fastener;
• aligning the pendent legs of the mounting clip with the channel of the frame rail and applying a force so as to insert the pendent legs into the channel such that the mating surface of each of the pendent legs engages the lip of a respective one of the flanges;
• and
• using a fastener, securing an edge portion of the PV module to the mounting clip, comprising securing an engaging end of the fastener within the opening of the support end of the mounting clip and thereafter turning the fastener in a securing direction so as to clamp down the edge portion of the PV module.