Abstract:
A clamp for securing a module to a rail. The clamp has a bolt having a head and a thread. The clamp includes an insert thread having a threaded aperture for receiving the thread of the bolt. The clamp having a body including an aperture to receive the bolt and wherein a first side of the body abuts the head of the bolt. The body includes a saw-toothed edge on a second side of the body opposing the first side of the body. The clamp includes a nut having a nut aperture for receiving the insert thread and the insert thread facilitating an electrical connection between the bolt and the nut. The nut having a first nut flange and a second nut flange extending toward the head of the bolt and wherein tightening of the bolt causes the nut and the body to approach one another causing the saw-toothed edge to pierce the module and the first nut flange and the second nut flange to engage and pierce notches of the rail.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application is a divisional application of U.S. application Ser. No. 12/470,682, entitled “Universal End Claim,” filed May 22, 2009 now U.S. Pat. No. 8,585,000, which claims priority to U.S. Provisional Patent Application Ser. No. 61/071,891, entitled “Device and Method for Solar Panel Installation,” filed May 22, 2008, which are hereby incorporated by reference in their entirety. This application is related to U.S. patent application Ser. No. 12/470,697, entitled “Module Attachment Apparatus and Method,” filed May 22, 2009, and U.S. patent application Ser. No. 12/470,588, entitled “Camming Clamp for Roof Seam,” filed May 22, 2009. 
    
    
     FIELD OF THE INVENTION 
     The invention relates generally to a clamp for securing a solar module or other component to a rail. 
     BACKGROUND 
     Solar energy generation is a rapidly growing technology worldwide and offers the potential of almost unlimited clean and sustainable energy. However, the use of solar electric technology has been limited by the costs associated with installing solar panels to existing and new structures and facilities. 
     When installing a solar module on a rail, various clamps must be utilized due to the varying sizes of the modules and various rail configurations. As a result, it is desirable to have a clamp that can be used to secure different types of modules to different types of rails. 
     The solar module is often installed on a roof or other surface for exposure to sunlight. As a result, the installed solar module can be viewed. Accordingly, it is desirable to have a clamp that is aesthetically pleasing and is preferably hidden under the module frames. 
     Because maintenance may be required for the solar modules and because the solar modules may be installed on a roof or other surface where access is often needed, safety is also an important consideration. Modules can be installed at a variety of heights, commonly about three to eight feet off the ground, and on a variety of surfaces, such as a roof of a building. When someone is walking next to a solar module, it is desirable that the rail does not extend past the edge of the module. 
     SUMMARY OF THE INVENTION 
     Various embodiments described herein attempt to overcome the drawbacks of the conventional techniques and devices for solar cell array installation. 
     The systems, methods, and devices described herein can offer, among other advantages, decreased cost of installing solar cell arrays or components thereof. This can be accomplished in an efficient and robust manner compared with the current installation techniques and devices. The systems, methods, and devices can be installed without drilling components during installation. Also, the modular nature can allow for easier installation and breakdown. 
     In one embodiment, a clamp comprises a body, a wedged channel nut, and a bolt. The body has a first component extending from the body and configured to engage a module and a second component having a tapered body surface. The wedged channel nut has a first flange and a second flange extending from opposing sides of the nut and configured to engage a rail and a tapered nut surface having an angle substantially identical to the angle of the tapered body surface of the second component, wherein the tapered nut surface engages the tapered body surface. A bolt extends through the wedged channel nut and the body. When the bolt is tightened, the nut and the body secure the module and rail together. 
     In another embodiment, a system comprises a module, a rail configured to support a module; and a clamp. The clamp includes a body including a first component extending from the body and configured to engage a surface of the module; and a second component having a tapered body surface. The clamp also includes a nut including a first flange and a second flange extending from opposing sides of the nut and configured to engage opposing sides of the rail; and a tapered nut surface having an angle substantially identical to the angle of the tapered body surface of the second component, wherein the tapered nut surface engages the tapered body surface. A bolt extends through the nut and the body. When the bolt is tightened, the nut and the body secure the module and rail together. 
     In yet another embodiment, a clamp comprises a body, a nut, and a bolt. The body includes a first component extending from the body and configured to engage a module; a second component extending from the body and configured to engage a first slot in a rail; and a third component having a tapered body surface. The nut includes a tapered nut surface having an angle substantially identical to the angle of the tapered body surface of the third component, wherein the tapered nut surface engages the tapered body surface; and a nut extension having a nut flange configured to engage a second slot of the rail. A bolt extends through the nut and the body. Tightening of the bolt causes the nut and the body to secure the module and rail together. 
     In another embodiment, a clamp comprises a bolt extending at least a width of a module; a body having an aperture to receive the bolt and a body flange extending from the body toward the module; and a nut having a nut aperture for receiving the bolt and a first nut flange and a second nut flange extending from the module. Tightening of the bolt causes the nut and the body to secure the module and rail together, wherein the body flange is configured to pierce the module, and wherein the first nut flange and the second nut flange are configured to pierce the rail. Piercing of the rail and module surface finishes can ensure electrical and grounding conductivity between all of the associated components. 
     Additional features and advantages of an embodiment will be set forth in the description which follows, and in part will be apparent from the description, or may be learned by practice of the invention. The objectives and other advantages of the invention will be realized and attained by the structure particularly pointed out in the exemplary embodiments in the written description and claims hereof as well as the appended drawings. 
     It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory and are intended to provide further explanation of the invention as claimed. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The preferred embodiments of the present invention are illustrated by way of example and not limited to the following figures: 
         FIG. 1   a  shows a cross-sectional view of single bolt universal module end clamp in a first installation position according to an exemplary embodiment. 
         FIG. 1   b  shows a cross-sectional view of single bolt universal module end clamp in a second installation position according to an exemplary embodiment. 
         FIG. 1   c  shows a cross-sectional view of single bolt universal module end clamp in a third installation position according to an exemplary embodiment. 
         FIG. 1   d  shows an end view of single bolt universal module end clamp in a final installation position according to an exemplary embodiment. 
         FIG. 1   e  shows an exploded view of a module end clamp according to an exemplary embodiment. 
         FIG. 1   f  shows an assembled view of a module end clamp according to an exemplary embodiment. 
         FIG. 1   g  shows an exploded view of an installed module end clamp according to an exemplary embodiment. 
         FIG. 2   a  shows a perspective view of a module end clamp in a first installation position according to an exemplary embodiment. 
         FIG. 2   b  shows a perspective view of a module end clamp in a second installation position according to an exemplary embodiment. 
         FIG. 2   c  shows a perspective view of a module end clamp in a third installation position according to an exemplary embodiment. 
         FIG. 2   d  shows a perspective view of a module end clamp in an installed position according to an exemplary embodiment. 
         FIG. 2   e  shows a perspective view of a module end clamp in an installed position according to an exemplary embodiment. 
         FIG. 3   a  shows a cross-sectional view of a universal module end clamp for a side-slot style rail according to an exemplary embodiment. 
         FIG. 3   b  shows a side view of a universal module end clamp for a side-slot style rail according to an exemplary embodiment. 
         FIG. 4   a  shows a cross-sectional view of a grounding channel nut and mid clamp securing two modules to a parallel rail according to an exemplary embodiment. 
         FIG. 4   b  shows a cross-sectional view of a grounding channel nut and mid clamp securing two modules to a perpendicular rail according to an exemplary embodiment. 
         FIG. 4   c  shows a cross-sectional view of a grounding channel nut and mid clamp securing two modules to a perpendicular rail according to an exemplary embodiment. 
     
    
    
     DETAILED DESCRIPTION 
     Reference will now be made in detail to the preferred embodiments of the present invention, examples of which are illustrated in the accompanying drawings. 
       FIGS. 1   a  to  1   d  show an installation of a single bolt universal module end clamp  100  for securing a solar module  110  to a rail  120 .  FIGS. 1   e  and  1   f  show perspective views of the components of the module end clamp  100 .  FIG. 1   g  shows an exploded view of an installed module end clamp  100 . Although a solar module is described herein, it is intended to include any component of a solar cell array to be secured, including, but not limited to, a photovoltaic array, a photovoltaic module, a solar cell, a rail, a solar panel, a solar tracker, a mounting post or pole, and a mounting bracket. However, the term module is not intended to be limited to components used for solar energy and solar component installation. The module can apply to any component that can be secured to a roof, including, but not limited to, a satellite dish, an antenna, and HVAC equipment. Also, although the clamp may be referred to as an end clamp, the clamp can be used at any location along a rail to secure a module. Additionally, in some embodiments, the clamp may be configured as a mid clamp. 
     The exemplary module  110  shown represents an end portion of the module  110 . The module  110  includes a frame  110   a  that extends perpendicular to and supports a solar panel glass  110   b . On a distal end of the frame  110   a  opposite the solar panel glass  110   b , the frame  110   a  includes a flange  110   c  extending perpendicular to the frame  110   a  in a direction beneath the solar panel  110   b . The flange  110   c  shown is merely exemplary, but it is common for various configurations of modules to include a flange. The underside of flange  110   c  is flat and is configured to abut a flat, upper surface of the rail  120 . Although this exemplary module is shown, it is intended that any configuration of module can be used. 
     The rail  120  can be secured by a variety of means to a roof or other surface for mounting the solar module for exposure. As shown in the cross-sectional view in  FIG. 1   d , the rail  120  can be constructed of a single material, such as anodized aluminum. In this exemplary embodiment, the rail  120  has a first vertical component  120   a  and a second vertical component  120   b  that are substantially connected by a horizontal component  120   c  to form a void  120   d  that can receive the clamp  100 . The first vertical component  120   a  and the second vertical component  120   b  can be used to support the module  110  and abut or engage an installed wedged channel nut  140 . 
     The end clamp  100  has an end clamp body  130 , an end clamp wedged channel nut  140 , and a torque bolt  150 . The body  130  has a horizontal component  130   a  and a vertical component  130   b  extending perpendicular to the horizontal component  130   a . At a distal end of the horizontal component  130   a , the body  130  has a flange  130   c  extending downwardly and perpendicular from the horizontal component  130   a . The vertical component  130   b  extends into a nut-receiving component  130   d  that extends outwardly in a direction away from the horizontal component  130   a . In a direction parallel to the horizontal component  130   a , the nut-receiving component  130   d  tapers to a point  130   e.    
     The wedged channel nut  140  has a first surface  140   a  that is flat and configured to abut a flat surface of the rail  120 . The wedged channel nut has a second surface  140   b  configured at an angle substantially identical to the angle of the tapered nut-receiving component  130   d . A third surface  140   c  is perpendicular to the first surface  140   a  and is configured so that it can abut a flat surface of the vertical component  130   b . A fourth surface  140   d , which faces a direction away from the body  130 , is configured to receive the bolt  150  through an aperture  140   e , shown in  FIG. 1   d . The aperture  140   e  is elongated and is configured to allow movement of wedged channel nut  140  in a vertical direction while maintaining the position of the bolt  150 . 
     The bolt  150  extends through the wedged channel nut  140  and into the body  130 . The body  130  has a threaded aperture for receiving a threaded component  150   a  of the bolt  150 . The bolt  150  can engage or disengage the wedged channel nut  140  and the body  130  by using torque to rotate a polygonal component  150   b  at a distal end of the bolt  150 . It is intended that the bolt  150  can have any configuration at the distal end that allows a user to rotate the bolt or allows the bolt to engage or disengage, such as a screwdriver receiving recess, and is not limited to a polygonal component, such as a hexagonal or pentagonal shaped component. In this exemplary embodiment, when the bolt  150  is completely tightened, a distal end of the threaded component  150   a  can extend past the nut-receiving component  130   d  of the body  130 . 
     As shown in  FIG. 1   a , the module  110  can be secured to the rail  120  by lowering the module  110  onto the rail  120 , whereby the clamp  100  does not obscure the alignment of the module  110  and the rail  120 . The bolt  150  and wedged channel nut  140  are in an initial position whereby the wedged channel nut is at a first position resting along nut receiving component  130   d.    
     Referring to  FIG. 1   b , the module  110  is aligned with the rail  120 . The clamp  100  can be guided such that the horizontal component  130   a  and flange  130   c  of the body  130  are positioned above the flange  110   c  of the module  110 . Additionally, the wedged nut channel  140  is positioned beneath the rail  120  and substantially aligned with the flange  110   c . Once the clamp  100  is substantially in this position, the bolt  150  can be tightened so that the wedged channel nut  140  engages the body  130  to secure the module  110  to the rail  120 . 
       FIG. 1   c  shows a cross-sectional view of the module  110  and the rail  120  having a substantially installed clamp  100 .  FIG. 1   d  shows an end view of the module  110  and rail  120  having an installed clamp  100 . Torque is applied to the bolt  150  causing the threaded component  150   b  to engage the aperture of the body  130  and extend beyond the aperture in the nut receiving component  130   b . As the bolt  150  is rotated, the second surface  140   b  of the wedged channel nut  140  slides along the nut receiving component  130   d . As the wedged channel nut  140  slides along the nut receiving component  130   d , the module  110  and the rail  120  are held together by a force pushing down by the flange  130   c  of the body  130  and a force pushing up from the wedged channel nut  140 . These forces, which are maintained by the position of the bolt  150 , cause the clamp  100  to lock the module  110  against the rail  120 . The amount of tightening of the bolt  150  required to secure the module  110  to the rail  120  can depend upon the thickness of the module  110  and the thickness of the rail  120 . 
     As shown in  FIGS. 1   d ,  1   e , and  1   f , the wedged channel nut  140  has a first flange  140   f  and a second flange  140   g , each of which extend along a side of the wedged channel nut  140  in a direction substantially parallel to the direction of the bolt  150 . As the wedged channel nut engages the rail  120 , the first flange  140   f  and the second flange  140   g  can enter a recess in the rail  120  or be configured to puncture a surface of the rail  120 . The first flange  140   f  and the second flange  140   g  force the rail  120  in a direction towards the module  110 . 
     By installing the clamp  100  on the module  110  and the rail  120 , a solar cell array or components thereof can be secured together without drilling into either component. By securing the rail  120  to a roof or other support surface, the module  110  can be supported and positioned without any damage to the module  110 . Also, by reversing the process described above, the clamp  100  can be uninstalled in a similar fashion. 
       FIG. 1   g  shows an exploded view of the installed clamp  100  securing the module  110  to the rail  120 . Because the installed clamp  100  is set back slightly from an edge of the rail  120 , a cap  160  can be installed on the rail  120 . The cap  160  can include a plurality of cap extensions  160   a  that are inserted into the rail  120  to frictionally engage the rail  120 . In one exemplary embodiment, the cap  160  can be made of rubber, though any known material to one of the art can be used. The installation of the cap  160  allows a flush end of the rail  120 , which is safer than exposing the sharp edges of the rail  120  and can be more aesthetic. 
       FIGS. 2   a  to  2   e  show a perspective view of an installation of a clamp is shown according to another exemplary embodiment. As shown in  FIG. 2   a , a clamp  200  can be slid into an end of a channel in a rail  210  such that a head of a bolt  200   a  remains exposed to an installer. A clamp body  200   b  and a wedged channel nut  200   c  of the clamp  200  are configured to be received by the rail  210  having a standard configuration. As shown in  FIGS. 2   b  and  2   c , the installer can continue to slide the clamp  200  into the rail  210 . As shown in  FIG. 2   d , once the clamp  200  has been slid a few centimeters into the rail  210 , a module  220  can be positioned on the rail  210 . The process to secure the module  220  to the rail  210  occurs similar to the method described above in  FIGS. 1   a  to  1   c , wherein the clamp  200  is tightened by bolt  200   a  to secure the module  220  to the rail  210 . The bolt  200   a  remains visible and accessible to the installer, who can use a drill, screwdriver, pliers, wrench, or other tool to tighten the bolt  200   a  of the clamp  200 .  FIG. 2   e  shows a perspective view of an installed clamp  200 . 
       FIGS. 3   a  and  3   b  show a module end clamp  300  configured for securing a module  310  to a side slot style rail  320 . Similar to the module end clamp shown in  FIGS. 1   a  to  1   g , the module end clamp  300  has a body  330 , a nut  340 , and a bolt  350 . The body  330  has a horizontal component  330   a  and a vertical component  330   b  extending perpendicular to the horizontal component  330   a . At a distal end of the horizontal component  330   a , the body  330  has a flange  330   c  extending downwardly and perpendicular from the horizontal component  330   a . The vertical component  330   b  extends into a nut-receiving component  330   d  that extends outwardly in a direction away from the horizontal component  330   a . In a direction parallel to the horizontal component  330   a , the nut-receiving component  330   d  tapers to a point  330   e.    
     The bolt  350  extends through the nut  340  and into the body  330 . The body  330  has a threaded aperture for receiving a threaded component  350   a  of the bolt  350 . The bolt  350  can engage or disengage the nut  340  and the body  330  by using torque to rotate a polygonal component  350   b  at a distal end of the bolt  350 . It is intended that the bolt  350  can have any configuration at the distal end that allows a user to rotate the bolt or allows the bolt to engage or disengage, such as a screwdriver receiving recess, and is not limited to a polygonal component, such as a hexagonal or pentagonal shaped component. In this exemplary embodiment, when the bolt  350  is completely tightened, a distal end of the threaded component  350   a  can extend past the nut-receiving component  330   d  of the body  330 . 
     Because the rail  320  is configured differently than the rail shown in  FIGS. 1   a  to  1   d , the nut  340  can also be configured differently. The rail  320  has a first slot  320   a  for receiving a bolt head, whereby a bolt is used to secure the module  310  to the rail  320 . The rail  320  has a second slot  320   b  for receiving a second bolt head for securing the rail to a support on a surface. The body  330  of the clamp  300  has a downward extending flange that engages the first slot  320   a  when the bolt  350  is tightened. The nut  340  has an aperture  340   a  for receiving the bolt  350 . The nut  340  also has a nut flange  340   b  that extends into the second slot  320   b . A second nut flange  340   c  extend from the nut flange  340   b  toward a side of the second slot  320   b . When the bolt  350  is tightened, the body  330  and the nut  340  engage each other as well as the rail  320  to secure the module  310 . 
       FIGS. 4   a  to  4   c  show a cross-sectional view of a grounding mid clamp  400  secured to a grounding channel nut  410  according to an alternative exemplary embodiment. The mid clamp  400  receives a bolt  420  that extends from an upper end of the mid clamp  400 , which is positioned above a module  430 , and past the other end of the module  430  through the grounding channel nut  410 . The grounding channel nut  410  can be secured in a rail  440  supporting the module  430 . The mid clamp  400 , bolt  420 , and grounding channel nut  410  are preferably made from a conductive material that is harder than the module and rail materials (e.g., aluminum) and does not rust or oxidize, such as stainless steel. 
     The mid clamp  400  has teeth  400   a  that extend toward the module  430 . As the bolt  420  is tightened, the teeth  400   a  can puncture an anodized aluminum module  430  to create an electrical ground path from the bolt  420 . 
     The grounding channel nut  410  has teeth  410   a  extending in a substantially upward direction. When the bolt  420  is tightened, the grounding channel nut  410  moves in a direction closer to the mid clamp  400 . The teeth  410   a  of the grounding channel nut  410  puncture the rail  440  to create an electrical ground path in the rail  440 . Stainless PEM insert threads  450  can ensure electrical conductivity from the bolt  420  to the grounding channel nut  410 . 
     As shown in  FIG. 4   a , the rail  440  runs in a direction substantially parallel to a seam between the two modules  430 . However, the mid clamp  400  can also be used in a configuration where the rail  440  runs perpendicular to the seam between the two modules, as shown in  FIGS. 4   b  and  4   c . As further shown in  FIG. 4   c , the mid clamp  400  can have a saw-toothed edge  400   b  to grip the module  430 . In one embodiment, the edge  400   b  can puncture the anodized aluminum module  430 . 
     The various embodiments of a clamp and the components thereof described herein can be composed of any known or convenient material, including, but not limited to metal, fiberglass, plastic, wood, composites or any other combination of materials. The clamp can be manufactured by any process known in the art, including extrusion and cold-forging. 
     The embodiments described above are intended to be exemplary. One skilled in the art recognizes that numerous alternative components and embodiments that may be substituted for the particular examples described herein and still fall within the scope of the invention.