Patent Publication Number: US-2019199271-A1

Title: Improved solar module mounting systems using a module connector and processes thereof

Description:
RELATED APPLICATION 
     The application claims priority from U.S. Provisional Application having Ser. No. 62/378,646 filed on Aug. 23, 2016, which is incorporated herein by reference for all purposes. 
    
    
     FIELD 
     The present teachings generally relate to module mounting systems and processes relating thereto. More particularly, the present teachings relate to systems and processes for mounting one or more modules (e.g., solar modules) using a module connector to a support structure, such as a rooftop. 
     BACKGROUND 
     Conventional solar module mounting systems use numerous interconnecting components to mount one or more solar module to a support structure. Unfortunately, they are typically heavy and involve a cumbersome assembly process. Additionally, they do not allow modules to be installed adjacent to each other, and, therefore, consume an inordinate amount of real estate on the support structure. These drawbacks of the conventional solar module mounting design detract from the renewable energy advantages obtained from solar cell applications. By way of example, heavy and complicated conventional module mounting systems suffer from increased transportation costs and installation costs. To this end, specialized equipment such as lifts or cranes are typically needed to lift components of the module mounting systems from the ground to a support structure (e.g., rooftop) typically located high above the ground. Moreover, complicated designs, which require numerous components, prolong the solar module installation process. As another example, the inordinate amount of real estate consumed by the conventional mounting systems prevents a requisite number of modules to be installed in a particular area of the support structure. Without the installation of a sufficient number of solar modules, the advantages of renewable solar energy are not realized. This problem is further exacerbated when the support structure does not include a large surface area to begin with. 
     What is, therefore, needed are novel systems and processes for effectively mounting modules to support structures that do not suffer from the drawbacks encountered by the conventional mounting designs. 
     SUMMARY OF THE INVENTION 
     To this end, the present arrangements and teachings provide lightweight module mounting systems and processes relating thereto. The present mounting systems effectively and simply install and secure multiple modules adjacent to each other with minimal or no gap between each module. 
     In one aspect, the present arrangements provide improved module mounting systems. One such exemplar module mounting system includes: (1) one or more support rails; (2) one or more module rails; and (3) one or more module connectors. 
     Each support structure is designed to attach to a support structures (e.g., rooftop) and includes an extending portion. Each module rail is designed to attach to one or more modules and includes an engaging surface and sidewalls that are configured to define, inside the module rail, a channel cavity. Furthermore, the sidewalls of each module rail include one or more internal lip features that extend towards and along a length of the channel cavity. Each internal lip feature defines one or more locking surfaces. 
     Each module connector is designed to couple at least one support rail to at least one module rail. Moreover, the module connector includes a support structure receiving portion having defined therein a receiving cavity, which has one or more inner receiving surfaces. Additionally, each module connector includes an outer boundary of a contacting surface, and further includes one or more connecting portions, each of which includes one or more lockable surfaces. 
     In an assembled configuration of one exemplar present mounting system, one or more module connectors are inserted into one or more module rails such that contacting surface of each module connectors contacts an engaging surface of one module rail and/or another module rail. Further, one or more lockable surfaces of each module connector engage with one or more locking surfaces of one module rail and/or another module rail. The engagement between the lockable surface and the locking surfaces lock one or more module connectors inside one or more module rails. Additionally, an extending portion of each support rail is received inside the receiving cavity of each module connector. In this configuration, one or more module connectors couple to one or more support attachment rails. 
     In one preferred embodiment of the present arrangements, one end of one of the module rail includes a notch to facilitate connection of one module rail with another module rail and is designed to receive the support rail. In another preferred embodiment of the present arrangements, internal lip features of the module rail include open edges. Each open edge has a curved profile that bends towards an extending portion and/or channel cavity. In yet another preferred embodiment of the present arrangements, the module rail is fastened to a solar module using a module fastening assembly. 
     In one embodiment to the present arrangements, the support structure is a rafter of a roof structure. In an attached configuration of the support structure and the support rail, the support rail is disposed in a direction that is perpendicular to an extending direction of the rafter. Preferably, each support rail is secured to multiple rafters. 
     In another embodiment of the present arrangements, the extending portion of each support rail has protruding sidewalls that are designed to contact the inner receiving surfaces a module connector. Preferably, dimensions of the inner receiving surfaces of each module connector are slightly larger than dimensions of the protruding sidewalls of each support rail. In assembled configuration of the present mounting systems, the protruding sidewalls are secured inside one of the inner receiving surfaces by frictional contact. More preferably, the protruding sidewalls are secured inside the inner receiving surfaces by a fastening assembly that fastens one of the protruding sidewalls to one of the inner receiving surfaces. In yet another implementation of the present arrangements, approximate open edges of a support rail&#39;s extending portion includes one or more support internal lip features, each of which includes a curved profile bending towards the extending portion and/or simple profile that does not include a curved profile. The curved profile defines a pathway for fasteners that facilitates simply and rapid coupling of the support structure and the support rail. 
     The mounting systems, in one embodiment further includes a support fastening assembly that fastens the support rail to a support structure such that a space is defined between the support rail and the support structure to allows for moisture or rain to travel. 
     A module connector, in one embodiment of the present arrangements, includes a first connecting portion having a connector fin, which has one or more lockable surfaces. In an assembled configuration of the present mounting system, one or more lockable surfaces of the connector fin engage with one or more locking surfaces of the module rail. 
     In another embodiment of the present arrangements, the module connector includes a second connection portion having an additional contacting surface and external sidewalls, which have, at a location approximate to an end, one or more additional lockable surfaces. In assembled configuration of a module connector and a module rail, one or more of the additional lockable surfaces engage with one or more of the locking surfaces of the module rail. 
     In another embodiment of the present arrangements, the inner receiving surface of the module rail is defined by two or more opposing sidewalls 
     The contacting surface of each module connectors, in certain embodiments of the present arrangements, contacts the engaging surface of a module rail and/or another module rail. In another embodiment of the present arrangements, one or more lockable surfaces of each module connectors engages with one or more locking surfaces of one module rail and/or another module rail. 
     In yet another aspect, the present teachings provide a process for mounting a module. The process of mounting a module may begin with a step (i). This step includes obtaining one or more module rails. A module rail includes an engaging surface and sidewalls that are configured to define, inside each module rail, a channel cavity. The sidewalls include one or more internal lip features that extend towards and along a length of the channel cavity, and the internal lip features define one or more locking surfaces. 
     Next, a step (ii) is carried out. This step includes securing to one or more modules one or more of said module rails to form one or more module sub-assemblies. 
     Then, step (iii) may follow or is carried out prior to step (ii) and includes obtaining one or more support rails, each of which includes an extending portion. 
     Following step (iii), in a next step (iv) support connecting subassemblies may be formed. Specifically, this step includes coupling to one or more support structures one or more support structure attachment rails to form one or more support connecting subassemblies. 
     Once module subassemblies and support connecting subassemblies are formed, they are ready for coupling. To this end, step (v) includes connecting, using one or more module connectors, one or more module subassemblies and one or more support connecting subassemblies. A module connector includes a support structure receiving portion that has defined therein a receiving cavity having inner receiving surfaces. A module connector also includes an outer boundary of a contacting surface and one or more connecting portions, each of which includes one or more lockable surfaces. In one embodiment of the present teachings, connecting includes inserting one or more module connectors into one or more module rails. In this assembled configuration, the contacting surface of each module connector contacts the engaging surface of one and/or another module rail and one or more lockable surfaces of each module connector engages with one or more locking surfaces of one and/or another module rails to lock one or more module connectors inside one or more module rails. In another embodiment of the present teachings, connecting further includes receiving the extending portion of each support rail inside each receiving cavity of each module. In this assembled configuration, one or more module connectors couple to one or more support attachment rails. 
     In one embodiment of the present teachings, coupling or securing involves using an adhesive and/or a fastening assembly. The present teachings and arrangements also recognize that the above-mentioned process steps need not be carried out in the order or sequence described above and may be carried out in any number of other orders or sequences. By way of example, one or more of the support connecting subassemblies are formed prior to forming one or more of the module subassemblies. 
     The construction and method of operation of the present teachings and arrangements, however, together with additional objects and advantages thereof, will be best understood from the following descriptions of specific embodiments when read in connection with the accompanying figures. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1A  shows cross-sectional view of a support rail, according to one embodiment of the present arrangements, for attaching to a support structure, such as a rooftop, on one side and for attaching to a module connector on another side, and the support rail includes a lip portion disposed at the end of sidewalls that define a cavity near a center region of the support rail. 
         FIG. 1B  shows an isometric view of the support rail shown in  FIG. 1A . 
         FIG. 2A  shows cross-sectional view of a support rail, according to another embodiment of the present arrangements and that does not include a lip portion disposed at the end of sidewalls that define a cavity near a center region of the support rail. 
         FIG. 2B  shows an isometric view of the support rail of  FIG. 2A . 
         FIG. 3  shows a cross-sectional view of a support connecting subassembly, according to one embodiment of the present arrangements, and that includes the support rail of  FIG. 1A  that is coupled to a support structure. 
         FIG. 4  shows a top view of a mounting subassembly, according to one embodiment of the present arrangements and that includes multiple support connecting subassemblies of  FIG. 3  overlying a rooftop structure, which includes multiple rafters disposed in a direction perpendicular to the extending directions of the support rails. 
         FIG. 5  shows a cross-sectional view of a module rail, according to one embodiment of the present arrangements and that couples to a module connector at one end and couples to a module (e.g., solar module) at another end. 
         FIG. 6  shows a side-sectional view of a module subassembly, according to one embodiment of the present arrangements and that includes two module rails of  FIG. 5  coupled to a module, and at least one of the module rails include a notched region that facilitates the coupling of two different modules and/or coupling of a module and a support structure. 
         FIG. 7  shows a cross-sectional view of the module subassembly of  FIG. 5 , according to one embodiment of the present arrangements and that includes two module rails coupled to a module, and the two module rails facilitates connection to another module subassembly and/or coupling of a module to a support structure. 
         FIG. 8  shows a cross-sectional view of a module connector, according to one embodiment of the present arrangements and that, in one assembled configuration of the present mounting system, couples a module rail to a support rail. 
         FIG. 9  shows a cross-sectional view of a module connector, according to another embodiment of the present arrangements and that includes a connector fin, and that, in one assembled configuration of the present mounting system, couples one module rail to another module rail, and couples one or more module rails to a support rail. 
         FIG. 10  shows a cross-sectional view of a module connector, according to yet another embodiment of the present arrangements and that includes a connector fin and a framed connecting portion, and that, in one assembled configuration of the present mounting system, couples one module rail to another module rail, and couples one or more module rails to a support rail. 
         FIG. 11A  shows an exploded cross-sectional view of a mounting system subassembly, according to one embodiment of the present arrangements and that includes a module connector that is capable of securing two module subassemblies to a support connecting subassembly. 
         FIG. 11B  shows cross-sectional view of a mounting system subassembly of  FIG. 11A  in an assembled configuration. 
         FIG. 12  shows a cross-sectional view of multiple mounting system subassemblies, according to one embodiment of the present arrangements and that are arranged to secure two adjacent modules. 
         FIG. 13  shows a top view of a module mounting system, according to one embodiment of the present arrangements and that has mounted thereon numerous modules in a grid-like fashion. 
     
    
    
     DETAILED DESCRIPTION OF THE DRAWINGS 
     In the following description, numerous specific details are set forth in order to provide a thorough understanding of the present teachings and arrangements. It will be apparent, however, to one skilled in the art that the present teachings and arrangements may be practiced without limitation to some or all of these specific details. In other instances, well-known process steps have not been described in detail in order to not unnecessarily obscure the present teachings and arrangements. 
     The present teachings and arrangements provide improved module support systems and processes relating thereto that are discussed in greater detail below. In one preferred embodiment of the present arrangements, the mounting systems include one or more module connectors and rails, which couple to one or more modules and that couple to one or more support structures. In this embodiment, the module connector effectively functions as an intermediate component that couples rails associated with modules to those that are associated with the support structures. For sake of clarity, rails associated with modules are hereinafter referred to as module rails and in one assembled configuration of the mounting systems, the module rails couple to modules. Similarly, rails associated with support structures are hereinafter referred to as support rails and in one assembled configuration of the mounting systems, the support rails couple to support structures. 
       FIGS. 1A and 1B  show a support rail  102 , according to one embodiment of the present arrangements. Support rail  102  includes a base surface  104  coupled to a first support sidewall  106  and a second support sidewall  108 . As shown in  FIGS. 1A and 1B , first support sidewall  106  and a second support sidewall  108  are opposing sidewalls having exterior surfaces that define an extending portion  110 . As discussed below, in an assembled configuration of present mounting systems, extending portion  110  occupies a receiving cavity (e.g., receiving cavity  1008  of  FIG. 8 ) in the module connector. 
     In the embodiment shown in  FIGS. 1A and 1B , the inner surfaces of opposing first support sidewall  106  and second support sidewall  108  define a support cavity towards a center region of support rail  102 . As explained below, in certain embodiments of the present arrangements, at least a portion of a fastening assembly (e.g., fastener  236  of  FIG. 3 ) resides in or occupies the support cavity and facilitates connection to a support structure and/or associated rails. In one implementation of this design, the fastening assembly specifically attaches base surface  104  to a support structure and/or an associated rafter. Further, in this implementation, base surface  104  may have defined therein one or more apertures, each of which receives at least a portion of the fastening assembly (e.g. connecting pins, lag bolts and screws). 
     Preferably, support rail  102  includes one or more properties chosen from a group comprising high bending strength, low weight, low cost, fire resistant, corrosion resistant, UV resistant, electrically non-conductive, high strength at low and high temperatures, and low coefficient of thermal expansion. Further, support rail  102  is preferably made from at least one material chosen from a group comprising aluminum, galvanized steel, reinforced plastic with fibers of glass, polymer or carbon. In an even more preferred embodiment of the present arrangements, support rail  102  is made of glass-reinforced pultruded lineals, which includes most, if not all, of the above-listed properties and is easy to drill and cut. 
       FIGS. 2A and 2B  show a support rail  102 ′, according to another embodiment of the present arrangements. In this embodiment, support rail  102 ′ includes a base surface  104 ′, a first support sidewall  106 ′, a second support sidewall  108 ′, and an extending portion  110 ′ that are substantially similar to their counterparts in in  FIG. 1A , i.e., support rail  102 , base surface  104 , first support sidewall  106 , second support sidewall  108  and extending portion  110 , except first and second support sidewalls  106 ′ and  108 ′ do not include an internal lip portion and each of these sidewalls have a uniform thickness along their length. The embodiment shown in  FIGS. 2A and 2B  uses less material and is easier and/or faster to manufacture (e.g., easily extrude). 
     In another embodiment of the present arrangements that is different from both the embodiments shown in  FIGS. 1A / 1 B and in  FIGS. 2A / 2 B, a cross-section of support rail  102 ′ has defined therein a support cavity defined towards a center region. This support cavity may be square or rectangular shaped. In other words, in this embodiment the support rail is akin to square-shaped, hollow tube that extends along a length. One or more apertures defined along a length of this support rail, receive a fastener such that the fastener, from that position, secures base surface  104  to support structure (e.g., support structure  230  of  FIG. 3 ). 
       FIG. 3  shows a support rail  202  fastened to support structure  230  to form a support connecting subassembly  225 . A fastener  236  fastens support rail  202  to support structure  230 . Support rail  202  and its base surface  204 , as shown in  FIG. 3 , are substantially similar to support rail  102  and base surface  104  of  FIG. 1 . In this assembled configuration of the support connecting subassembly, a gap  238  exists between base surface  204  and supporting surface  232 . By way of example, gap  238  may be achieved by positioning one or more spacers along the length of support rail  202  between base surface  204  and supporting surface  232 . In the presence of an angled supporting surface  232 , gap  238  provides space for rainwater and other accumulated material to drain away from the module mounting system. In another embodiment of the present arrangements, base surface  204  is disposed adjacent to and contacts a supporting surface  232  of support structure  230  so that gap  238  does not exist. 
     Support structures, upon which a module is ultimately secured, may be of different types. One common type of support structure  230  is a rooftop that includes one or more rafters  234 . The present arrangements, in one implementation, contemplate disposing support rail  202  above one or more rafters (e.g., rafter  234 ). A support fastening assembly (e.g., a fastener such as a lag bolt)  236  couples support rail  202  to rafter  234  at one point of intersection (of support rail  202  and rafter  234 ) to form support connecting subassembly  225 . In this configuration, the weight of a module (e.g., a solar module), the mounting system and any downward forces cause by environmental conditions (e.g., wind, rain, and, hail) are distributed to one or more rafters. 
       FIG. 4  shows a top view of a mounting subassembly  240  that includes one or more longitudinally extending support rails  202 ′ that are designed to receive an array of modules. By way of example, module rails and/or module connectors, which are discussed in greater detail in connection with  FIGS. 5-10, 11A and 11B , are used to connect modules to one or more of longitudinally extending support rails  202 ′ of  FIG. 4 . Each support rail  202 ′ includes one or more support connecting subassemblies  225 ′ that connect support rail  202 ′ to support structure  230 ′. Thus, using mounting subassembly  240  numerous modules are disposed adjacent to each other with minimal spaces therebetween and in a grid-like fashion above a support structure. In other words, mounting subassembly  240  allows an array of solar panels to be effectively secured to a support structure without consuming an inordinately large amount of space, a drawback of the conventional module mounting systems. This design feature of the present module mounting systems allow, for example, numerous solar panels to harness a maximum amount of solar power to properly exploit the advantages of renewable solar energy. 
     In mounting subassembly  240 , rafters  234  (shown by dotted lines) of support structure  230 ′ (and corresponding rafters) extend in a direction that is perpendicular to longitudinally extending support rails  202 ′ and alternate ones of rafters  234  have installed thereon support connecting subassembly  225 ′, which is shown in greater detail in  FIG. 3 . However, the present arrangements are not so limited. Support connecting subassembly  225 ′ may be installed on any of the rafters  234  so long as support rail  202 ′ is secured to supporting surface  230 ′. 
       FIG. 5  shows a module rail  452 , according to one embodiment of the present arrangements and that includes a module contacting surface  454 , a first module sidewall  456 , and a second module sidewall  458 . In an assembled configuration, module contacting surface  454  is coupled to or secured to a portion of a module (e.g., a solar module). Module rail  452  also includes a channel cavity  466 , extending along a length of module rail  452 . As shown in  FIG. 5 , channel cavity is defined by an engaging surface  464  and surfaces of first module sidewall  456 , and second module sidewall  458 . 
     Each of first module sidewall  456  and second module sidewall  458  include an internal lip feature  460  that extend towards channel cavity  466 . Specifically, as shown in  FIG. 5 , the open edges of internal lip feature  460  have a curved profile that bend towards channel cavity  466 . 
     Importantly in the embodiment of  FIG. 5 , a locking surface  462  is defined at the end of each internal lip feature  460 . In one preferred embodiment of the present arrangements, wherein a plurality of locking surfaces are being used, each locking surface has the same height, i.e., each locking surface extends to the same plane that is parallel to engaging surface  464 . As will be explained later, in an assembled configuration of the present mounting systems, module rail  452  couples to a module connector (e.g., module connector  1000  of  FIG. 7 ) such that each locking surface  462  and/or engaging surface  464  engages or couples with corresponding ones of a lockable surface (e.g., lockable surface  1006  of  FIG. 8 ) and contacting surface (e.g., contacting surface  1020  of  FIG. 8 ), respectively. Stated another way, engagement or coupling of each locking surface  462  and/or engaging surface  464  with corresponding ones of a lockable surface (e.g., lockable surface  1006  of  FIG. 8 ) and contacting surface (e.g., contacting surface  1020  of  FIG. 8 ), respectively, generates a locking mechanism that locks module connector (e.g., module connector  1000  of  FIG. 7 ) into place with module rail  452  of  FIG. 5 . 
       FIG. 5  shows one embodiment of module rail  452 . However, the present arrangements are not so limited. By way of example, module rail  452  may include a single sidewall (i.e., first module sidewall  456  having an internal lip feature  460  and accompanying locking surface  462 ). In this configuration, module rail  452  receives a module connector and locking surface  462  and engaging surface  464  engage with the lockable surface and the contacting surface of the module connector. As another example, internal lip features  460  of first module sidewall  456  and second module sidewall  458  connect to form an enclosed, or hollow, module rail  452 . In this example, the module rail has a square or rectangular tube-like appearance. Consequently, locking surface  462  may extend along a portion or the entire length of module rail  452  and is on an opposing internal surface to engaging surface  462 . In a configuration where the module rail couples to the module connector, a locking surface of the module rail engages or couples to a lockable surface of the module connector along the entire length or a portion of the module connector to form a very strong connection between the module rail and the module connector. According to the present arrangements, such strong connections allow a plurality of module connectors to be connected to a single module rail. 
     Module rail  452  may be selected from the same material group as support rail  102 . However, it is preferable for module rail  452  to be electrically non-conductive to prevent an electrical path to the ground. In one preferred embodiment of the present arrangements, module rail  452  is made from the same or similar material as the material of the module&#39;s contacting surface, i.e., the surface of the module that directly contacts the module rail. In this embodiment, module rail  452  and the module&#39;s contacting surface, preferably, have similar coefficients of thermal expansion as this tends to reduce stresses that may develop when the present mounting systems, during use, are subjected to a broad range of temperatures. 
       FIG. 6  shows a side-sectional view of a module subassembly  470  that includes a longitudinally extending module rail  451  and at least a portion of a module  475  (e.g., solar module). Module rail  451  is substantially similar to module rail  452  of  FIG. 5 , except module rail  451  has defined, at one end, a notch  468 . As shown in  FIG. 6 , notch  468  excludes a portion of the sidewalls of module rail  451  (e.g., excludes a portion of first module sidewall  456  and second module sidewall  458  of  FIG. 5 ). Further, notch  468  includes an engaging surface  464 , which is also shown in connection with module rail  452  in  FIG. 5 . In an assembled configuration of the present mounting systems, a module connector&#39;s contacting surface may engage with engaging surface  464  of notch  468 . As will be explained later in connection with a mounting subassembly, notch  468  facilitates connection of one module rail with another module rail and is designed to receive a support rail (e.g., support rail  202  of  FIG. 2 ). Notch  468 , therefore, may couple and support two adjacent solar modules and may serve as a location for coupling to a support rail. 
       FIG. 7  shows a cross-sectional view of a module subassembly  470 ′ that includes module rails  451 ′ and  453 ′ coupled to a portion of module  475 ′. Module rails  451 ′ and  453 ′ are substantially similar to module rail  452  of  FIG. 4 . The present arrangements recognize that module subassembly  470 ′ may have any number of module rails, which function to support the weight of one or more attached modules and any additional weight caused by environmental conditions. Module rails may also provide rigidity to one or more of the attached modules. When used in combination with a rectangular solar module the number of rails may depend on the orientation in which the solar module is to be installed. By way of example, for an installation in which the longer edge of the solar module is longitudinal, three vertical rails may be installed along a length of the solar module. However, for an installation in which the longer edge of the solar module runs perpendicular to the longitudinal extension of the solar module, two vertical rails may be installed along the length of the solar module. 
       FIG. 8  shows a module connector  1000 , according to one embodiment of the present arrangements and that includes a support rail receiving portion  1002 , a connecting portion  1004 , and a contacting surface  1020  (which is an exterior surface of connecting portion  1004 ). Module connector  1000  extends longitudinally. Further, contacting surface  1020  of module connector  1000  couple to or engages with engaging surface  464  along a length of module rail  452  shown in  FIG. 5 . 
     In one embodiment of the present arrangements, connecting portion  1004  of module connector  1000  of  FIG. 8  includes sidewalls that have, at a location approximate to an end of the sidewalls, one or more lockable surfaces  1006  that engage with the locking surfaces (e.g., locking surfaces  462  shown in  FIG. 5 ) of module rail (e.g., module rail shown in  FIG. 5 ). 
     In addition to engaging with one or more module rails, module connector  1000  may also engage with a support rail (e.g., support rail  102  shown in  FIG. 1 ). This may be accomplished many number of ways. In one preferred embodiment of the present arrangements, support rail receiving portion  1002  of module connector  1000  of  FIG. 8  includes one or more inner receiving surfaces  1010  that define a receiving cavity  1008 . In module connector  1000 , preferably, two or more receiving sidewalls that are disposed opposite to each other define inner receiving surface  1010 . During an assembled configuration of the present mounting systems, receiving cavity  1008  is designed to receive an extending portion (e.g., extending portion  110  of  FIG. 1A ) of a support rail (e.g., support rail  102  of  FIG. 1A ). In an assembled configuration of the present mountings systems, one or more of inner receiving surfaces  1010  may be disposed adjacent to and contacting extending portions  110  of support rail  102  of  FIG. 1A . Preferably, a fastening mechanism fastens the receiving surfaces of the receiving cavity to the extending portions of the support rail further strengthening the connection between the ultimately used support structure, through support connecting subassembly (e.g., support connecting subassembly  225  of  FIG. 3 ) and the module connector, which ultimately connects to a module. 
     Module connector  1000  may be selected from the same material list as support rail  102 . In one preferred embodiment of the present arrangements, module connector  1000  is made of aluminum. 
       FIG. 9  shows module connector  2000 , according to another embodiment of the present arrangements and that, in addition to a receiving cavity  2008 , includes at least one connecting portion  2005 . Module fastener  2000  is substantially similar to module connector  1000  of  FIG. 7  (i.e., module fastener  2000  includes a support rail receiving portion  2002 , a connecting portion  2004 , a lockable surface  2006 , and a receiving cavity  2008  that are substantially similar to support rail receiving portion  1002 , connecting portion  1004 , lockable surface  1006 , and receiving cavity  1008  of  FIG. 7 ). As shown in  FIG. 9 , in addition to connecting portion  2004 , module connector  2000  includes another connecting portion  2005 , which, in turn, includes a connector fin  2012  having associated lockable surfaces  2014 . During an assembled configuration of the present mounting systems and similar to lockable surfaces  2006  of connecting portion  2004 , lockable surfaces  2014  of another connecting portion  2005  engage with the locking surfaces (e.g., locking surfaces  462  shown in  FIG. 5 ) of a module rail (e.g., module rail shown in  FIG. 5 ). Thus, in an assembled configuration of the present mounting systems, the lockable surfaces associated with the two different connecting portions engage with the locking surfaces of the same or two different module rails to engage with that or two different module rails. In the configuration where the lockable surfaces associated with two different connecting portions engage with locking surfaces of two different module rails, the lockable surfaces allow coupling of two different modules that are ultimately secured on the two different module rails. Further, each of the contacting surfaces associated with the connecting portion (e.g., connecting portion  2004 ) and the support rails receiving portion (e.g., support rail receiving portion  2002 ) contact or engage with the same or two different engaging surfaces (e.g., engaging surface  465  of  FIG. 5 ) associated with one or two different module rails to form a stronger coupling or connection between module connector  2000  and one or two different module rails. Such couplings between a module connector and the same or two different module rails is explained in greater detail below in connection with  FIGS. 11A and 11B . 
       FIG. 10  shows module connector  2000 ′, according to yet another embodiment of the present arrangements and that includes a connecting portion  2004 ′ that is different than connecting portion  2004  of  FIG. 9 . Module connector  2000 ′ of  FIG. 10  is substantially similar to module connector  2000  of  FIG. 9  (i.e., module fastener  2000 ′ includes a support rail receiving portion  2002 ′, a connecting portion  2004 ′, another connecting portion  2005 ′, a connector fin  2012 ′, and another lockable surfaces  2014 ′ that are substantially similar to support rail receiving portion  2002 , connecting portion  2004 , another connecting portion  2005 , connector fin  2012 , and another lockable surfaces  2014  of  FIG. 9 ). The difference between module connectors  2000 ′ and  2000  of  FIGS. 10 and 9 , respectively, is that connecting portion  2004 ′ of module connector  2000 ′ includes a framed structure  2018 , which has defined thereon a framed lockable surface  2016 , and connecting portion  2004  does not have such a framed structure and framed lockable surface. In an assembled configuration of the present mounting systems, framed lockable surface  2016  couples to or engages with a locking surface (e.g., locking surface  462  of  FIG. 5 ) of a module rail (e.g., module rail shown in  FIG. 5 ). 
     Framed structure  2018  of  FIG. 10  contributes to the strength of the connection or coupling between module connector  2000 ′ and one or more module rails (e.g., module rail  452  shown in  FIG. 5 ). By way of example, the rigidity of framed structure  2018  allows framed lockable surface  2016  to effectively resist deflection produced by locking surfaces of the module rails, during an assembled state of the present mounting systems, by. Furthermore, an increased length of lockable surface  2016  is designed to engaged with a greater length of the locking surface of the module rail (e.g., locking surface  462  of  FIG. 5 ) of a module rail (e.g., module rail shown in  FIG. 5 ). In certain embodiments of the present arrangements, connecting portions  2004  and  2004 ′ of  FIGS. 9 and 10  are absent, and in these embodiments, presence of connector fin  2012  of  FIG. 9 or 2012 ′ of  10  is present along with support rail receiving portion  2002  of  FIGS. 9 and 2002 ′ of  FIG. 10  to facilitate forming a locking connection or coupling between module connector  2000  and  2000 ′ of  FIGS. 9 and 10  and a module rail (e.g., module rail  452  of  FIG. 5 ). 
       FIG. 11A  shows an exploded view of a mounting system subassembly  3000 , according to one embodiment of the present arrangements and that includes two module subassemblies  470 ( a ) and  470 ( b ), a module connector  2000 , and support connecting subassembly  2225 . Module subassemblies  470 ( a ) and  470 ( b ), which include module rails  451 ( a ) and  451 ( b ), respectively, are substantially similar to module subassembly  470 , which includes module rail  451  of  FIG. 6 . Module connector  2000  of  FIG. 11A  is the same as shown in  FIG. 9 . Furthermore, support connecting subassembly  2225  is substantially similar to support connecting subassembly  225  of  FIG. 2 . 
     In an assembled configuration of mounting system subassembly  3000 , module connector  2000  is inserted into a cavity (e.g., channel cavity  466  of  FIG. 5 ) of a module rail (e.g., module rail  452  of  FIG. 5 ). In  FIG. 11A , module connector  2000  is inserted into each of the channel cavities associated with module subassemblies  470 ( a ) and  470 ( b ), which are substantially similar to module subassembly  470  of  FIG. 6 . More specifically, in this inserted configuration, contacting surface  2020  of module connector  2000  engages with engaging surface  464 ( a ) of module rail  451 ( a ) and lockable surface  2006  of module connector  2000  engages with locking surface  462 ( a ) of module rail  451 ( a ). Similarly, contacting surface  2020  of module connector  2000  engages with engaging surface  464 ( b ) of module rail  451 ( b ) and lockable surface  2014  of module connector  2000  engages with locking surface  462 ( b ) of module rail  451 ( b ). Thus, one portion of module connector  2000  is secured within module rail  451 ( a ) and another portion of module connector  2000  is secured within  451 ( b ). Each module rails  451 ( a ) and  451 ( b ) may have at least two locations of contact with module connector  2000 . The first location of contact with module connector  2000  is along their associated engaging surfaces (e.g., engaging surface  464 ( a ) of module rail  451 ( a ) and engaging surface  464 ( b ) of module rail  451 ( b )). The second location of contact with module connector  2000  is at their associated locking surfaces (e.g., locking surface  462 ( a ) of module rail  451 ( a ) and locking surface  462 ( b ) of module rail  451 ( b )). 
     In addition to engaging with module subassemblies  470 ( a ) and  470 ( b ), module connector  2000  also engages with support connecting subassembly  2225 . To this end, an extending portion  110  of support rail  102  is received inside receiving cavity  2008 . In one embodiment of the present arrangements, the dimensions of inner receiving surfaces  2010  are slightly larger than the dimension of extending portion  110  such that extending portion  110  is secured inside one of inner receiving surfaces  2010 . 
     In another embodiment of the present arrangements, one or more inner receiving surfaces  2010  secures extending portion  110  by forming a frictional contact between one or more inner receiving surfaces  2010  and extending portion  110 . In yet another embodiment of the present arrangements, a fastener  2235  engages with extending portion  110  and one or more inner receiving surfaces  2010  to secure module connector  2000  to support connecting subassembly  2225 . 
       FIG. 11B  shows a mounting system subassembly  3000 ′, which is a depiction of an assembled state of mounting system subassembly  3000  of  FIG. 11A . It is clear from this figure, and as explained above in  FIG. 11A , that a portion of module connector  2000  engages with module subassemblies  470 ( a ) and a different portion of module connector  2000  engages with  470 ( b ) such that the module connector  2000  couples these two module subassemblies together. 
     Specifically, at least a portion of support rail receiving portion (e.g., support rail receiving portion  2002  of  FIG. 9 ) of module connector  2000  is positioned inside a notch (e.g., notch  468  of  11 B) that is defined on a module rail (e.g., module rail  451  of  FIG. 6 ) of module subassembly  471 ( b ). In one embodiment of the present arrangements, another portion of support rail receiving portion (e.g., support rail receiving portion  2002  of  FIG. 9 ) of module connector  2000  is positioned inside a channel cavity (e.g., channel cavity  466  of  FIG. 5 ) of module rail (e.g., module  452  of  FIG. 5 ) associated with module subassembly  470 ( a ). With regard to the remaining connecting portions (e.g., connecting portion  2004  and another connecting portion  2005  of  FIG. 9 , respectively), as explained above, the lockable surfaces (e.g., lockable surfaces  2006  and  2014  of  FIG. 11A ) of are in a locked position with locking surfaces (e.g., locking surfaces  462 ( a ) and ( b ) of  FIG. 11A ) of module rails (e.g., module rails  451 ( a ) and  451 ( b )). Further, a fastener  2235  may be used to further strengthen the coupling or connection between support connecting subassembly  2225  and module connector  2000 . In the assembled configuration of mounting system subassembly  3000 ′, a support connecting subassembly (e.g., support connecting subassembly  2225  of  FIG. 11B ) longitudinally extends and is secured inside a module connector (e.g., module connector  2000  of  FIG. 11B ) that extends preferably a width of one or more module rails (e.g., module rail  451 ( a ) and  451 ( b )). One or more of these module rails extend in another direction, preferably, perpendicular to the longitudinally extending support connecting subassembly. As a result and as explained above in connection with  FIG. 4 , many module rails are supported on one or more support rails of a mounting subassembly (e.g., mounting subassembly  240  of  FIG. 4 ). One or more module rails, in turn, supports one or more modules. 
     According to one embodiment of the present arrangements, different module connector designs (e.g.,  FIGS. 8, 9 and 10 ) are employed with respect to a particular support connecting subassembly (e.g., support connecting subassembly  225  of  FIG. 3 ), depending where that support connecting subassembly is disposed, whether the module subassembly has a notch, how many modules/module subassemblies are being coupled approximately on that particular support connecting subassembly, or the weight of the modules/module subassemblies that are being supported atop the particular support connecting subassembly. 
       FIG. 12  shows a partially arranged mounting system  3050 , according to one embodiment of the present arrangements. This partial arrangement is an exemplar that uses two different type of module connectors depending on their function. In this figure, module connectors of a first type  1000 ( a ) and  1000 ( b ) are used at either end points of a continuous module rail (e.g., module rail  451  of  FIG. 13 ). As shown in  FIG. 12 , a module connector of a second type  2000  is used to couple together two different type of module subassemblies  470 ( a ) and  470 ( b ) and also secure them above support connecting subassembly  2225 ( a ). Support connecting subassembly  2225 ( a ) and module subassemblies  470 ( a ) and  470 ( b ) are the same as they are shown in  FIG. 11A  and support connecting subassemblies  2225 ( a ),  2225 ( b ), and  2225 ( c ) are substantially similar to each other. 
     Module connectors of the first type  1000 ( a ) and  1000 ( b ) do not include connector fins (e.g., connector fin  2014  of  FIG. 9 ), as they are shown in connection with module connector  2000 . According to the present arrangements, connector fins need not be included when the module connector is being used adjacent to support connecting assemblies located at an end point of a continuous module rail. 
     Although the module connectors  1000 ( a ) and  1000 ( b ) are of the same type, they form a different type of connection with their associated module subassemblies  470 ( a ) and ( b ). By way of example, module connector  1000 ( a ) is received inside a notch  468 ( a ) defined at one end of module subassembly  470 ( a ), but it is not necessary to have a notch defined at the other end of module subassembly  470 ( b ) to receive module connector  1000 ( b ). At the other end of module subassembly  470 ( b ) module connector  1000 ( b ) is inserted into a channel cavity (e.g., channel cavity  466  of  FIG. 5 ) of a module rail (e.g., module rail  452  of  FIG. 5 ) and this type of insertion/engagement creates a sufficiently strong connection to connect the module subassembly  470 ( b ) to its associated underlying support connecting subassembly  2225 ( c ). To the extent additional security is required, a fastening mechanism may be used to secure module connectors  1000 ( a ) or  1000 ( b ) to support connecting subassemblies  2225 ( b ) and  2225 ( c ). 
     Mounting system  3050  also provides provisions for protection from environmental conditions. Specifically, flashing  2030  may be coupled to module subassembly  470 ( b ) and/or module connector  1000 ( b ) and extend to a supporting surface to cover and/or protect support connecting subassembly  2225 ( c ) from environmental conditions during use. 
       FIG. 13  shows a present mounting system  4000 , according to one embodiment of the present arrangements. Mounting system  400  includes a plurality of modules installed on a plurality of module subassemblies (e.g., module subassemblies  470 ( a ),  470 ( b ), and  470 ( c )) that are secured on a mounting subassembly (e.g., mounting subassembly  240  of  FIG. 3 ). As explained in  FIG. 4 , one or more support rails (e.g., support rails  202 ′ of  FIG. 4 ) are coupled to a support structure (e.g., support structure  230  of  FIG. 3 ). As a result, one or more modules (e.g., solar modules) are ultimately securely fastened to a support structure  230  (e.g., rooftop  230  that is supported by rafters  234  of  FIG. 3 ). 
     As shown in  FIG. 13 , a plurality of module rails (e.g., module rails  451 ( a ) and  451 ( b )) connects to form continuous module rail  451 .  FIGS. 11A and 11B  show that one or more module connectors (e.g., module connector  2000  of  FIG. 9 ) may be used to connect module rails  451 ( a ) and  451 ( b ). Other module rails may similarly connect to form continuous module rails  453 ,  455 , and  457 . Continuous module rails  451 ,  453 ,  455 , and  457  are perpendicular to support rails  201 ,  202 ,  205 ,  207 , and  209  (which are substantially similar to support rail  202  of  FIG. 2 ). In one preferred embodiment of the present arrangements, continuous module rails  453 ,  455 , and  457  are parallel to the underlying rafters (e.g., rafters  234  of  FIG. 3 ) when the presenting mounting systems are assembled on a rooftop. 
     The present mounting systems offer many advantages over their conventional counterparts. By way of example, present mounting system  4000  allow a plurality of modules to be disposed adjacent to each other without a minimal or no gap between adjacent modules. As a result, the amount of extensive space needed by the conventional mounting systems to install modules is obviated and a significantly greater number of modules may be installed per square feet of rooftop surface. As another example, one or more module connector couples strong subassemblies, i.e., a mounting subassembly and one or more module subassemblies, to form a mounting system that has great mechanical strength to overcome the challenges posed by the environmental conditions and inclement weather elements. Moreover, the present mounting systems represents a lightweight design that lowers transport and installation costs. The risks of having a heavy object installed on a rooftop are also eliminated. 
     The present teachings also provide novel processes of mounting a module (e.g., a solar module) using the mounting system of the present arrangements. In one embodiment of the present teachings, the process preferably begins with a step of obtaining one or more module rails (e.g., one or more module rails  452  of  FIG. 5  and module rail  451  of  FIG. 6 ). Preferably, each module rail includes an engaging surface and sidewalls that are configured to define, inside each of the module rail, a channel cavity. In one embodiment of the present teachings, each sidewall includes an internal lip features that extend inside and along a length of the channel cavity. The internal lip features define one or more locking surfaces. In yet another embodiment of the present teachings, a portion of module rail includes a notch (e.g., notch  468  of  FIG. 6 ), which in an assembled configuration is designed to receive an extending portion (e.g., extending portion  110  of  FIG. 1A ) of the support rail (e.g., support rail  102  of  FIG. 1A ). 
     Another step includes securing one or more of module rails to one or more modules to form one or more module subassemblies (e.g., module subassembly  470  of  FIG. 5 ). In certain embodiments of the present teachings, each module subassembly includes two or more module rails. 
     A next step includes obtaining one or more support rails, each of which includes an extending portion. Another step includes coupling one or more support rails to a support structure to form one or more support connecting subassemblies (e.g., support connecting subassembly  225  of  FIG. 2 ). A fastening mechanism (e.g., fastener  236  of  FIG. 3 ) may secure each support rail to the support structure. In a preferred embodiment of the present teachings, one or more rafters (e.g., rafter  234  of  FIG. 2 ) provide mechanical support to the support rails. 
     The mounting process proceeds to a step of connecting one or more module subassemblies and one or more support connecting subassemblies. A module connector connects a module subassembly to a support connecting subassembly. Each module connectors includes a support structure receiving portion that has defined therein a receiving cavity having inner receiving surfaces. Module connector also includes an outer boundary of a contacting surface and includes one or more connecting portions, each of which includes one or more lockable surfaces. 
     The step of connecting a module subassembly and a support connecting subassembly includes inserting a module connector into one or more module rails such that contacting surface of the module connector contacts the engaging surface of one and/or another module rail. In this inserted position, one or more lockable surfaces of the module connector engages with one or more locking surfaces of one and/or another module rail to lock the module connector inside one and/or another adjacent module rails. 
     The step of connecting a module subassembly and a support connecting subassembly also includes receiving the extending portion of each support rails inside each module connector&#39;s receiving cavity such that each module connectors couple to a support attachment rail. 
     Although illustrative embodiments of the present teachings and arrangements are shown and described in terms of solar modules, other modifications, changes, and substitutions are intended. By way of example, other type of modules, which are different from solar modules, may well be used in connection with the present teachings and arrangements. Accordingly, it is appropriate that the disclosure be construed broadly and in a manner consistent with the scope of the disclosure, as set forth in the following claims.