Abstract:
In various representative aspects, an apparatus for securing and covering clamp assembly that secures and electrically binds a solar panel module to a mounting rail as part of a solar panel array is provided that is both easy and efficient to install.

Description:
FIELD OF THE INVENTION 
       [0001]    The present invention relates generally to an apparatus for securing and covering a clamping assembly used to connect and ground multiple objects together. In particular, the clamping assembly is similar to the assemblies that have been disclosed in U.S. Publication 2015/0311606 (“the &#39;606 Publication”) that clamp and electrically bonds a solar panel module to a solar panel mounting rail. More specifically, the invention is a sleeve that fits and snaps onto the clamping assembly and enables the assembly to serve as an end clamp in the solar panel array. 
       BACKGROUND OF INVENTION 
       [0002]    The installation of solar panel arrays on residential roofs can be arduous and time-consuming. Depending on the array design, the components required to install the array can make the installation process even more difficult. Many of the assembly components require special tools or are generally difficult to install because they are utilized after the solar panels modules are arranged or positioned on their support elements. This is particularly true when the elements must be installed on a roof that links to a rail guide for supporting the solar panel array. 
         [0003]    In a typical support rail guide system, solar panel modules are arranged across the top of several rail guides. This may occur, for example, by using mounting clamps that secure solar panel modules along the top of the rail guide. The rail guides in turn are supported to a roof by flashings. 
         [0004]    The clamping devices, like those disclosed in the &#39;606 Publication, which this application incorporates by reference, are examples of clamping assemblies used to secure a solar panel module to the top of a rail guide. These clamping assemblies are typically installed as a mid-clamp within the solar panel array. When positioned along the lower end of the solar panel array, the clamp assembly is exposed and can have an unsightly appearance. The present invention provides a sleeve that fits and snaps onto the clamp assembly and covers the assembly so that the assembly can be used as an end clamp without exposing the parts of the assembly on the lower end of the array. The present invention is also easy to install, use, and manufacture. 
       SUMMARY OF THE INVENTION 
       [0005]    The invention is summarized below only for purposes of introducing embodiments of the invention. The ultimate scope of the invention is to be limited only to the claims that follow the specification. 
         [0006]    It is an object of this invention to provide an apparatus for covering a clamp assembly that is used to secure a solar panel module to a rail guide structure. 
         [0007]    It is a further object of this invention that the apparatus is a sleeve that fits on an elongated portion of the clamp. 
         [0008]    It is a further object of this invention that the apparatus can snap on to the elongated portion of the clamp assembly. 
         [0009]    It is a further object of this invention that the clamp provides a cover for the clamp assembly that prevents exposure of the clamp to open view. 
         [0010]    It is a further object of this invention that the elongated portion of the clamp assembly is the elongated portion described and illustrated in the &#39;606 Publication. 
         [0011]    A person with ordinary skill in the relevant art would know that any shape or size of the elements described below may be adopted. Any combinations of suitable number, shape, and size of the elements described below may be used. Also, any materials suitable to achieve the object of the current invention may be chosen as well. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0012]    A more complete understanding of the present invention may be derived by referring to the detailed description and claims when considered in connection with the following illustrative figures. In the following figures, like reference numbers refer to similar elements and steps throughout the figures. 
           [0013]      FIG. 1  illustrates a top perspective view of an exemplary clamp assembly. 
           [0014]      FIG. 2  illustrates a bottom perspective view of the clamp assembly shown in  FIG. 1 . 
           [0015]      FIG. 3  illustrates a rear perspective view of an exemplary clamp assembly sleeve. 
           [0016]      FIG. 4  illustrates a front perspective view of the clamp assembly sleeve in  FIG. 3 . 
           [0017]      FIG. 5  illustrates a perspective view of a pre-assembled combination of the clamp assembly sleeve and the clamp assembly as shown in  FIGS. 1-4 . 
           [0018]      FIG. 6A and 6B  illustrate side and front perspective views of the assembled clamp assembly and clamp assembly sleeve. 
           [0019]      FIG. 7  illustrates a front perspective view of a fully assembled clamp assembly and clamp assembly sleeve in use while securing a solar panel module to a rail guide. 
           [0020]      FIG. 8  illustrates a cross-section view of the assembled product shown in  FIG. 7 . 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0021]    In the following description, and for the purposes of explanation, numerous specific details are provided to thoroughly understand the various aspects of the invention. It will be understood, however, by those skilled in the relevant arts, that the present invention may be practiced without these specific details. In other instances, known structures and devices are shown or discussed more generally to avoid obscuring the invention. In many cases, a description of the operation is sufficient to enable one to implement the various forms of the invention, particularly when the operation is to be implemented in software. It should be noted that there are many different and alternative configurations, devices and technologies to which the disclosed embodiments may be applied. The full scope of the invention is not limited to the example(s) that are described below. 
         [0022]      FIGS. 1 and 2  show top and bottom perspective views respectively of an exemplary embodiment of a clamp assembly  100 . The clamp assembly  100  is the clamp described and disclosed in  FIGS. 9-13  of the &#39;606 Publication, although the present invention can also be used with a clamp assembly that utilizes an elongated female member similar to that described below. The clamping assembly  100  includes a male member  130  and an integrated female member  140 . The integrated female member  140  is also referred to as a binding bolt and is typically cylindrically shaped. This exemplary clamp assembly in this embodiment is a rounded head mid-clamp clamping assembly  100  defines an integrated structure, such that all the elements of the female member are one piece. Together the members  130  and  140  define a fastener that is used to fix solar panel modules to a mounting rail/racking system. 
         [0023]    The male and female members,  130  and  140  are interlocking. The male member has an elongated male element defining a threaded shank  135  and an enlarged end defining a T-bolt end  110 . The T-bolt end  110  includes at least one raised portion  120  that is designed for penetrating the surface treatment layer of the solar panel mounting rails and may also include a roller  180 . In the embodiment shown, there are a plurality of raised portions  125  defining teeth, which create a pre-determined pattern. The pattern facilitates the penetration of the surface treatment layer of the rails by the male member  130  with only a pressure fit. Additionally, in the embodiment shown, the male member  130  is electrically conductive and made from electrically conductive material. 
         [0024]    Likewise, the entire female member  140  is also electrically conductive. The female member  140  defines an integrated member that includes a nut end  150 , an annular ring  160  defining a piercing member  170 . The nut end  150  is not limited to a conventional hexagonal nut and can comprise any drive type capable of advancing the female member  140  by hand or with a tool such as a torx or allen drive. The female member  140  includes an elongated female element  145  that is generally cylindrical and extends from the nut end  150 . Each of the above elements are integrated as if they are a single unit with no movement with respect to one another, but alternatively the elongated female member  145  and the annular ring  160  can be separate elements as long as the annular ring  160  is free to move along the elongated female member  140 . 
         [0025]    The elongated male element  130  has defines the threaded shank  135 . The elongated female element  140  defines a sheath and has internal threads which are functionally compatible with the external threads  135  (also shown in  FIG. 10B  of the &#39;016 application. Thus, the above-described structure provides an adjustable interlocking fastener assembly for among other things mounting solar panel frames on support rails. 
         [0026]    The piercing member  170  includes washer with an annular ring  160  and a center opening. The center opening is sized and shaped to allow the elongated female member  140  passage through the center opening. Additionally, the annular ring  160  has a raised portion for penetrating a metal frame as described above. The raised portion defines the piercing member  170 . The piercing member  170  has an edge sharp enough to pierce the surface treatment layer of the solar panel mounting rail as best seen in  FIG. 7 . 
         [0027]    As shown in  FIG. 7 , the rounded head mid-clamp  100  is used to affix a solar panel frame  400  to a mounting rail  300 . The rounded head mid-clamp  100  is typically used to clamp solar panel frames  400  side-by-side and the mounting rail  300  that runs under and perpendicular to the frames  400 . The solar panel module includes a rear side  410  and a bottom  430 . The male and female members,  130  and  140  respectively, are connected by loosely screwing the members together. The elongated portions  135  and  145  of the male and female portions respectively, thereby form a vertical member, which is vertically aligned with the channel  310  of mounting rail  300 . The mounting rail  300  also includes a hollow center  320 . 
         [0028]    As illustrated, the T-bolt end  110  is adjustable and rotates with respect to the female member  140 . After alignment, the female member is pressed against the rear side  410  of the frame  400  with the penetrating member  170  piercing the surface treatment layers of frame  400 . The T-bolt end  110  is turned so that it fits within the channel  310 . Upon proper placement, so that the T-bolt end  110  fits squarely into the channel, the nut end  150  is tightened. The nut end  150  is tightened until raised portions or teeth  125  pierce the surface treatment layer inside the channel  310 . The installer uses one hand to tighten the nut end  150 , while the other hand is simply there to guide the fastener so that assembly retains its proper positions. It will be understood that since the female member has already been affixed to the top panel  400  as illustrated, the rounded head mid-clamp  100  can in most instances be installed one-handed. 
         [0029]    With particular reference to  FIGS. 3 and 4 , an exemplary sleeve  200  is shown. The sleeve  200  fits onto the clamp assembly  100  and serves as an end clamp for the clamping assembly  100 . The sleeve  100  typically snaps into place over the binding bolt  140  on the clamping assembly  100 . An exemplary embodiment of the sleeve  200  includes an outer cover  220  that is typically semi-cylindrical, a connector  210  that is also generally semi-cylindrically shaped, and a rear support  230 . The diameter of the outer cover  220  is typically the same as the nut end  150  of the clamp assembly  100 , but it could be less if desired. The connector  210  is integrated with the outer cover  220 , and in an alternate embodiment, the outer cover  220  could serve as the connector  210  if it is desired that the outer cover  220  does not have to be the same or similar diameter to that of the nut end  150  or annular ring  160  of the nut end  150 . In  FIGS. 3 and 4 , the connector  210  is joined by extensions perpendicularly coupled to the outer cover  220 , but it is understood that the connector  210  could be fully integrated with the outer cover  220  as well. The connector  210  is typically made from a resilient material that and, as shown in  FIG. 5 , engages the binding bolt  140  by snapping directly over it so that the binding bolt  140  fits within a portion of the connector  210  until it contacts the rear support  230 . The rear support  230  extends perpendicularly from the rear of the connector  210 . The rear support  230  is optional, but in the present invention utilizes it for tactile feedback to notify the installer that the binding bolt  140  has been fully inserted. 
         [0030]      FIGS. 6A and 6B  show how the assembled sleeve  200  is connected to the clamp assembly  100 . As shown, the sleeve  200  is pushed onto the binding bolt  140  until it snaps securely into place within the connector  210  and reaches the rear support  230 .  FIG. 7  shows the sleeve  200  when it is connected to the clamp assembly  100  and when the clamp assembly  100  has been used to secure the solar panel module  400  to the mounting rail  300 . When fully assembled, the sleeve  200  enables the clamp assembly to act as an end clamp that secures the solar panel module  400  to the mounting rail on the perimeter of the solar panel array and keeps the extended male and female members hidden from view as shown in  FIGS. 6B and 7 . 
         [0031]      FIG. 8  shows a cross-sectional view of  FIG. 7 . The piercing member  170  also penetrates the surface layer of the sleeve  200 . By doing so, the sleeve  200  is electrically bonded to the clamp assembly  100 , the solar panel module  400 , and the mounting rail  300 .