Support Frame Assembly And Method Of Forming A Support Frame Assembly

Abstract

At least one aspect of the present invention is related to a support frame assembly for supporting a solar device, such as an array of mirror elements and/or photovoltaic panels. The support frame assembly includes a plurality of support arm assemblies, each of which includes a pair of rails and a plurality of web structures interconnecting the rails. Specifically, each of the web structures has a base which is attached to one of the rails and a pair of legs extending towards and attached to the other of the rails. The web structures are preferably formed through a single stamping process with at least one of the web structures being at least partially in a nesting relationship with another of the web structures.

1 . A support frame assembly for supporting a solar device, comprising:
 at least two rails at least partially spaced from one another and converging towards one another from a first end to a second end;   at least two web structures spaced from one another with each web structure extending between and being attached to said at least two rails; and   wherein at least one of said web structures has a base attached to one of said rails and at least two legs extending to the other of said rails and an opening between said legs.   
     
     
         2 . The support frame assembly as set forth in  claim 1  wherein at least one of said web structures is sized and shaped to nest within said opening of said at least one web structure with said base and said legs. 
     
     
         3 . The support frame assembly as set forth in  claim 2  wherein each of said web structures is generally U-shaped. 
     
     
         4 . The support frame assembly as set forth in claim I wherein each of said rails extends generally linearly. 
     
     
         5 . The support frame assembly as set forth in  claim 1  further including a torque tube extending generally perpendicularly to said pair of rails and wherein said first ends of said rails are attached to said torque tube. 
     
     
         6 . The support frame assembly as set forth in  claim 5  wherein said pair of rails and said web structures are part of a support arm assembly and further including a plurality of support arm assemblies spaced axially from one another along said torque tube. 
     
     
         7 . The support frame assembly as set forth in  claim 1  wherein each of said rails presents a pair of flanges and wherein one side of each of said web structures is sandwiched between said flanges of one of said rails and the other side of each of said web structures is sandwiched between said flanges of the other of said rails. 
     
     
         8 . The support frame assembly as set forth in  claim 7  further including a plurality of adjustable fasteners attached to one of said rails and extending generally upwardly therefrom for receiving an array of solar panels. 
     
     
         9 . The support frame assembly as set forth in  claim 1  wherein said rails are formed of a first material and said web structures are formed of a second material being lighter than said first material. 
     
     
         10 . A method of forming a support frame for a solar assembly, comprising the steps of:
 preparing at least two rails and a plurality of web structures with at least one of said web structures having a base and a pair of legs;   positioning the at least two rails in a predetermined configuration relative to one another; and   attaching the at least one base to one of the rails and the pair of legs to the other of the rails to interconnect the at least two rails and present a support arm assembly.   
     
     
         11 . The method as set forth in  claim 10  wherein the step of preparing the plurality of web structures is further defined as stamping a plurality of web structures through a single stamping process with at least one of the web structures being at least partially in a nesting relationship with another of the web structures. 
     
     
         12 . The method as set forth in  claim 10  wherein the step of preparing the at least two rails is further defined as roll forming the at least two rails. 
     
     
         13 . The method as set forth in  claim 10  further including the step of forming a plurality of support arm assemblies and a torque tube. 
     
     
         14 . The method as set forth in  claim 13  further including the step of attaching the plurality of support arm assemblies to the torque tube. 
     
     
         15 . The method as set forth in  claim 10  wherein the step of positioning the rails is further defined as positioning the two rails in a converging relationship relative to one another.