Solar panel clamp

A clamping apparatus secures a photovoltaic module to a rail. The clamping apparatus includes a bolt extending between a first end and a second end of the bolt. The clamping apparatus includes a clamp defining a bolt opening into which the bolt is received and a support structure. The support structure positions the clamp at a first location on the bolt. The first location is a first distance from a top rail surface plane within which a top surface of the rail lies. The support structure is adjustable to position the clamp at a second location on the bolt. The second location is a second distance from the top rail surface plane. The first distance is different than the second distance. The support structure has a support structure thickness corresponding to a third distance that is less than the first distance and less than the second distance.

BACKGROUND

The present application relates to, among other things, systems and/or methods for clamping photovoltaic (PV) modules to a rail and/or rail system configured to support the photovoltaic modules (e.g., to form a PV array).

Solar power often refers to the conversion of energy from sunlight to electricity (e.g., to power an appliance, car, home, business, etc.). Solar power generation has become increasingly popular given a shift away from producing electricity via fossil fuels (e.g., coal, oil, natural gas, etc.). Such an increase in popularity may be attributed to numerous factors. For example, the production of electricity via sunlight is considered to be more environmentally friendly than using fossil fuels (e.g., few to no pollutants are emitted using solar technology). Moreover, the conversion efficiency (e.g., amount of sunlight converted into electricity) has continued to increase while the cost to manufacture photovoltaic modules (e.g., solar panels) has decreased, allowing for more widespread applicability (e.g., both in terms of geographic location and affordability).

To convert sunlight or other light into electricity, one or more photovoltaic modules, comprised of a plurality of photovoltaic cells, may be used. Respective photovoltaic cells are configured to convert light energy (e.g., from the sun) into electricity via the photovoltaic effect (e.g., where a voltage and/or electric current is created in a material based upon exposure to light). Because the power that one module can produce is usually insufficient to meet a desired power output (e.g., to power a home and/or business), a plurality of photovoltaic modules may be operably coupled together and arranged to form a photovoltaic array. Traditionally, the photovoltaic modules have been arranged in a grid of rows or columns. However, in some applications, they may be arranged in a different pattern.

To secure the photovoltaic modules, a traditional rail and top-down clamping apparatus have been employed. The rails often comprise a channel and the clamping apparatus comprises a t-shaped bolt (e.g., also referred to as a “t-bolt”) that is designed to fit into the channel of the rail. In operation, the t-bolt is usually inserted into the channel and turned to a desired orientation relative the channel. A clamp of the clamping apparatus is then attached to the t-bolt and secured via a nut to mitigate movement of the module relative to the rail.

Typically, components of the clamping apparatus (e.g., the t-bolt, clamp, and nut) are shipped individually to the installation site and assembled once the modules have been set in place. That is, the module is set in place, the t-bolt is inserted into the channel, the clamp is attached to the bolt, the nut is attached to the bolt, and then the nut is tightened to secure the module (e.g., via the clamp). Given that a typical photovoltaic array comprises at least 12 modules, and may exceed 100 modules, and given that a plurality of clamping apparatuses may be used to secure respective modules, the installation process may be labor intensive (e.g., adding to the total cost of the photovoltaic array). Moreover, given that clamping apparatuses are assembled on site, bolts, clamps and/or nuts may be lost, dropped, etc. during the installation process, further increasing installation time and/or cost.

SUMMARY

In an example, a clamping apparatus is configured to secure one or more photovoltaic modules to a rail. The clamping apparatus comprises a bolt extending along a bolt axis between a first end of the bolt and a second end of the bolt. The second end of the bolt is configured to be received within the rail. The clamping apparatus comprises a clamp defining a bolt opening into which the bolt is received. The clamping apparatus comprises a support structure configured to position the clamp at a first location on the bolt when the second end of the bolt is received within the rail and the clamp does not secure the one or more photovoltaic modules to the rail. The first location is a first distance from a top rail surface plane within which a top surface of the rail lies where the first distance extends along a first distance axis that is parallel to the bolt axis and is measured from the top rail surface plane to a bottom surface of the clamp. The clamp is disposed to a first side of the top rail surface plane when the clamp is positioned at the first location and the second end of the bolt is disposed to a second side of the top rail surface plane when the second end of the bolt is received within the rail. The support structure is configured to position the clamp at a second location on the bolt when the second end of the bolt is received within the rail and the clamp does secure the one or more photovoltaic modules to the rail. The second location is a second distance from the top rail surface plane where the second distance extends along a second distance axis that is parallel to the bolt axis and is measured from the top rail surface plane to the bottom surface of the clamp. The clamp is disposed to the first side of the top rail surface plane when the clamp is positioned at the second location. The first distance is different than the second distance. The support structure has a support structure thickness corresponding to a third distance measured from a first end of the support structure to a second end of the support structure. The third distance extends along a support structure axis that is parallel to the bolt axis and is less than the first distance and less than the second distance.

In another example, a clamping apparatus is configured to secure one or more photovoltaic modules to a rail. The clamping apparatus comprises a bolt extending along a bolt axis between a first end of the bolt and a second end of the bolt. The second end of the bolt is configured to be received within the rail. The clamping apparatus comprises a clamp defining a bolt opening into which the bolt is received. The clamping apparatus comprises a support structure configured to position the clamp at a first location on the bolt when the second end of the bolt is received within the rail and the clamp does not secure the one or more photovoltaic modules to the rail. The first location is a first distance from a top rail surface plane within which a top surface of the rail lies where the first distance extends along a first distance axis that is parallel to the bolt axis and is measured from the top rail surface plane to a bottom surface of the clamp. The clamp is disposed to a first side of the top rail surface plane when the clamp is positioned at the first location and the second end of the bolt is disposed to a second side of the top rail surface plane when the second end of the bolt is received within the rail. The support structure is configured to position the clamp at a second location on the bolt when the second end of the bolt is received within the rail and the clamp does secure the one or more photovoltaic modules to the rail. The second location is a second distance from the top rail surface plane where the second distance extends along a second distance axis that is parallel to the bolt axis and is measured from the top rail surface plane to the bottom surface of the clamp. The clamp is disposed to the first side of the top rail surface plane when the clamp is positioned at the second location. The first distance is different than the second distance. The support structure comprises a first affixation that affixes the clamp to a nut configured to be threaded onto the bolt when the second end of the bolt is received within the rail and the clamp does not secure the one or more photovoltaic modules to the rail. The support structure has a support structure thickness corresponding to a third distance measured from a first end of the support structure to a second end of the support structure. The third distance extends along a support structure axis that is parallel to the bolt axis and is less than the first distance and less than the second distance.

In yet another example, a clamping apparatus configured to secure one or more photovoltaic modules to a rail. The clamping apparatus comprises a bolt extending along a bolt axis between a first end of the bolt and a second end of the bolt. The second end of the bolt is configured to be received within the rail. The clamping apparatus comprises a clamp defining a bolt opening into which the bolt is received. The clamping apparatus comprises a support structure configured to position the clamp at a first location on the bolt when the second end of the bolt is received within the rail and the clamp does not secure the one or more photovoltaic modules to the rail. The first location is a first distance from a top rail surface plane within which a top surface of the rail lies where the first distance extends along a first distance axis that is parallel to the bolt axis and is measured from the top rail surface plane to a bottom surface of the clamp. The clamp is disposed to a first side of the top rail surface plane when the clamp is positioned at the first location and the second end of the bolt is disposed to a second side of the top rail surface plane when the second end of the bolt is received within the rail. The support structure is configured to position the clamp at a second location on the bolt when the second end of the bolt is received within the rail and the clamp does secure the one or more photovoltaic modules to the rail. The second location is a second distance from the top rail surface plane where the second distance extends along a second distance axis that is parallel to the bolt axis and is measured from the top rail surface plane to the bottom surface of the clamp. The clamp is disposed to the first side of the top rail surface plane when the clamp is positioned at the second location, the first distance different than the second distance. The support structure has a support structure thickness corresponding to a third distance measured from a first end of the support structure to a second end of the support structure. The third distance extends along a support structure axis that is parallel to the bolt axis and is less than the first distance and less than the second distance. The third distance is less than about ½ of the second distance.

DESCRIPTION

FIG. 1illustrates an example photovoltaic array100(e.g., also referred to as a solar panel array, solar array, and/or the like) comprised of a plurality of photovoltaic modules102that are arranged along and/or attached to one or more rails104(e.g., substantially occluded by the overlying modules102). As illustrated herein, the rails104extend substantially parallel to the a-axis, although they may extend substantially parallel to the b-axis. Moreover, as will be described in further detail with respect toFIG. 2, respective rails further comprise a channel that runs along the length of the rails (e.g., in the example embodiment, channels run parallel to the a-axis).

Channels in the rails may be useful for securing the modules102to the rails104via one or more clamping apparatuses106,108. For example, in the illustrated embodiment, the modules102are secured to the rails104via end-clamp apparatuses106and mid-clamp apparatuses108. Generally, the differences between end-clamp apparatuses106and mid-clamp apparatuses108are merely based upon the number of modules the clamping apparatus is intended to secure and/or the location of the clamping apparatus. For example, in the illustrated embodiment, end-clamp apparatuses106are positioned on an edge of the array100and are respectively configured to secure merely one module102. Mid-clamp apparatuses108are positioned between modules102of the array100and are configured to secure two or more modules102, for example. As used herein, the terms clamping apparatus, clamping apparatuses, and/or the like are intended to be interpreted in a broad sense to comprise both end-clamp apparatuses106and mid-clamp apparatuses108.

While a specific rail type and/or structure configuration is shown in the examples described herein, it is to be understood that the clamping apparatus(es) described herein can be employed with alternative rail and/or attachments systems to the extent practical. Moreover, the number of modules comprised in the example array100, the arrangement of the array100, and/or the arrangement of the modules102relative to the rails104are not intended to limit the scope of the appended claims. Further, while specific reference is made to the applicability of the clamping apparatus for securing photovoltaic modules, it will be appreciated that the clamping apparatus(es) may find utility in other applications. Thus, to the extent practical, the instant disclosure, including the scope of the claims, is not intended to be limited to a clamping apparatus for securing photovoltaic modules.

FIG. 2illustrates a cross-sectional view of a photovoltaic array100(e.g., taken along line2-2inFIG. 1). As illustrated, a photovoltaic module102is situated on top of one or more rails104. The rails104are configured to accommodate a clamping apparatus (not shown) to secure the module102to the rail104. For example, in the illustrated embodiment, respective rails104comprise a channel206through which a portion of the clamping apparatus (e.g., a t-shaped or other-shaped head of the clamping apparatus (e.g., or, more particularly, of a bolt portion of the clamping apparatus)) may be inserted. However, other mechanisms for securing the clamping apparatus to the rail are also contemplated. For example, in another embodiment, the rail comprises an extruded portion to which the clamping apparatus attaches.

It will be appreciated that one or more of the rails104may further comprise other channels208,210that may be utilized to secure the rail to other rails and/or to secure the rail to a supporting structure (e.g., such as a roof or pole to which the photovoltaic array is attached), for example. Moreover, the shape of the rail, number and/or size of additional channels, etc. may depend upon, among other things, how the rails104are coupled together (e.g., if they are coupled together), a weight of the modules102, a structure to which the rails104attach, etc.

FIG. 3illustrates an exploded view of a clamping apparatus300(e.g.,106,108inFIG. 1) that may be configured to secure one or more photovoltaic modules102to a rail(s)104. It will be appreciated thatFIG. 3illustrates what is referred to above as a mid-clamp apparatus (e.g., based upon the size and/or shape of the clamp340), although the features described herein may also be applicable to end-clamp apparatuses.

The clamping apparatus300comprises a threaded bolt302, a grounding device312, a support structure320, a clamp340, and a nut360. It will be appreciated that at least some of these components may be optional and/or the clamping apparatus300may comprise additional components not described herein. For example, in one embodiment, the grounding device312(e.g., washer) may be optional.

The bolt302may comprise at least two ends (e.g., a first end304and a second end306), where the second end306may be defined by a head308that is configured to be inserted into a channel of a rail, for example. The bolt302can extend along a bolt axis310between the first end304of the bolt302and the second end306of the bolt302.

Typically, the head308has at least one dimension that is greater than a width of the channel, which reduces the possibility of the bolt302coming out of the channel once the head308is inserted into the channel and/or oriented as desired relative to the channel. By way of example, in the illustrated clamping apparatus300, the bolt302comprises a T-shaped portion or T-shaped head308. As will be further explained, such a bolt302is configured to (easily) slip into the channel of the rail when it is oriented in a first manner relative to the channel (e.g., when the more narrow dimension of the head308is perpendicular to the length of the channel) and to be secured in the channel when it is oriented in a second manner relative to the channel (e.g., when the more narrow dimension of the head308is parallel to the length of the channel). Alternatively, in another embodiment, the bolt302may not comprise a defined head308. Rather, a nut and/or other component may be coupled to the bolt302to substantially form a head that has at least one dimension that is greater than a width of the channel, for example.

The example clamping apparatus300comprises a grounding device312. The grounding device may be selectively coupled to a shaft of the bolt302and/or may be permanently affixed the bolt302. For example, in an embodiment, the grounding device312may comprise a washer with smooth and/or jagged surfaces. By way of example, the washer may comprises one or more teeth that are configured to mitigate rotation of the washer relative to the rail and/or are configured to pierce into the rail (e.g., comprised of an anodized aluminum) to provide a gas tight connection between the washer and the rail, for example (e.g., mitigating oxidation). It will be appreciated that by coupling the rail to the grounding device312as described, the clamping apparatus300and/or the photovoltaic module to which it is affixed may be ground to the rail. In this way, a ground wire may not be run to respective clamping apparatuses and/or to respective photovoltaic modules, for example.

In another embodiment, the grounding device312may be configured to attach to a ground wire that is coupled to ground wires from other clamping apparatuses and/or coupled to an earthing electrode (e.g., metal rod), for example. Such a feature may reduce undesired contact with a voltage should electrical components of the array fail, reduce build-up of electricity, and/or provide a channel for conducting high currents associated with lightning strikes, for example. As such, the grounding device312can function to electrically ground the bolt302.

It will be appreciated that the illustrated grounding device312(e.g., which has a shape similar to a washer) is merely one of numerous examples of grounding devices that may be utilized. In another embodiment, the grounding device312is a ground wire that is wrapped around, soldered, and/or otherwise attached to a portion of the clamping apparatus300, for example. It will be appreciated that in some examples, the grounding device312is optional and may not be provided.

The clamping apparatus300further comprises the support structure320configured to be selectively coupled to the shaft of the bolt302and/or permanently affixed to the bolt302. It will be appreciated that while the support structure is generally illustrated as having a concentric arrangement relative to the bolt302, the instant disclosure, included the scope of the appended claims, is not intended to be so limited. That is, unless specified to the contrary, any configuration(s), design(s), etc. are contemplated for the support structure (e.g., that facilitate the functions provided herein). The support structure320is also configured to position the clamp340of the clamping apparatus300a specified distance from the second end306(e.g., head308) of the bolt302and/or to position the clamp340a specified distance from (e.g., a top edge of) the rail once the clamping apparatus300is attached to the rail, for example.

The support structure320may be comprised of a compressible material and is configured to be compressed once the photovoltaic module is positioned appropriately relative to the rail to secure the module. That is, once the module is in the desired position, an installer, for example, may tighten the nut360, causing the support structure320to be compressed and reducing the space between the rail and the clamp340. Such compressible materials may comprise, but are not limited to, a spring (e.g., such as a rubber spring or metal spring), a gasket, a polystyrene, and/or a compressible metal structure (e.g., such as a soft metal). The support structure320defines a second bolt opening322into which the bolt302may be received.

The clamping apparatus300also comprises a clamp340configured to be selectively coupled to the shaft of the bolt302and/or permanently affixed to the bolt302. The clamp340defines a bolt opening342into which the bolt302can be received. The clamp340can secure one or more photovoltaic modules to the rail. For example, the clamp340may comprise one or more edges that are configured to extend over a portion of the module(s). When the nut360is selectively coupled to the shaft via the first end304of the bolt302and tightened, the one or more edges extending over the portion of the module may apply pressure to the module, causing the module to be secured to the rail. In this way, the nut360acts to secure the clamp340and the support structure320to the bolt302and/or to apply pressure to the clamp340and/or the support structure320when tightened, for example.

The clamping apparatus300may also comprise other features that promote safely securing the one or more modules to the rail, for example. By way of example, in an embodiment, the clamp340comprises one or more tabs344that are configured to contact a side-edge of one or more modules (e.g., as opposed to a top edge facing the sunlight) and/or to be partially inserted between two or more modules. Such tabs344are configured to reduce and/or mitigate rotation of the clamp relative to the module while the nut360is being tightened, for example.

FIG. 4illustrates a cross-sectional view (e.g., taken along line4-4inFIG. 3) of the bolt302.FIG. 5illustrates a top-down view of the clamp340. In some examples, the shaft of the bolt302may comprise a non-cylindrical portion (e.g., such as a flat/shaved edge) and the clamp340may comprise a non-cylindrical bolt opening342(e.g., of a similar shape to the non-cylindrical portion of the shaft) into which the non-cylindrical portion of the shaft is inserted. Such non-cylindrical features of the bolt302and the clamp340and/or the tabs344of the clamp may mitigate rotation of the bolt302, and the clamping apparatus300generally, relative to the rail once the bolt is inserted into the channel and turned appropriately (e.g., mitigating rotation of the bolt302as the nut360is being tightened). That is, stated differently, the one or more tabs344, the non-cylindrically shaped bolt opening342, and the non-cylindrically shaped portion of the bolt302may facilitate alignment of the second end306of the bolt302(e.g., the head308) within a channel of the rail, such that rotation of the bolt302relative to the channel is mitigated as the one or more modules are being secured (e.g., as the nut360is being tightened).

It will be appreciated that these and other features may be described in more detail in U.S. Patent Publication 2011/0299957 and assigned to Preformed Line Products Company, at least some of which may be incorporated herein by reference. For example, another feature of the bolt302may be that one or more edges of the head308of the bolt302are rounded while other edges are substantially square to control how the bolt302can be rotated within the channel of the rail. For example, in one embodiment, the head308comprises one round corner and three square corners such that the bolt can be rotated in merely one direction relative to the rail when the t-shaped head of the bolt is inserted into a channel of the rail (e.g., because the square corners limit rotation in other directions). Moreover, once turned to a specified position (e.g., turned 90 degrees relative to an initial position when the bolt/clamping apparatus is inserted into the channel (e.g., such that the head is substantially perpendicular to the channel as described further inFIGS. 7-8), the head308with merely one round corner may mitigate further rotation of the bolt302(e.g., to mitigate rotating the bolt further such that the head308becomes parallel with the channel).

FIG. 6illustrates a cross-sectional view (e.g., taken along line6-6inFIG. 1) illustrating a clamping apparatus300securing a photovoltaic module102to a rail104via a channel206. The clamping apparatus300comprises a bolt302comprising a head308that is inserted into the channel206of the rail104. The example clamping apparatus300also comprises a grounding device312, support structure320, clamp340including tabs344that abut the side of the module102, and a nut360.

FIGS. 7-8illustrate how a preassembled clamping apparatus300comprising a bolt302having a t-shaped head308may be selectively coupled to a rail104. More particularly,FIG. 7illustrates a portion of the clamping apparatus300being inserted into a channel206of the rail104. The t-shaped head308is turned such that a more narrow dimension710of the head308is perpendicular the length of the channel206(e.g., going into and out of the page), allowing the t-shaped head308to be lowered into the channel206.

Once the t-shaped head308is positioned in the channel206, the bolt302(e.g., and/or the entire clamping apparatus300) may be rotated712clockwise and/or counter-clockwise (e.g., 90 degrees) until the narrow dimension of the head308is parallel or substantially parallel to the length of the channel206(e.g., such that the narrow dimension of the head308is going into and/or out of the page) as illustrated inFIG. 8. It will be appreciated that this changed orientation of the head308relative to the channel206can reduce (e.g., mitigate) the possibility of the clamping apparatus300becoming unsecured from the rail104.

FIG. 9illustrates an example photovoltaic module102positioned adjacent the clamping apparatus300. In an example, the rail104comprises a top surface900. The top surface900can support and/or be positioned adjacent to a bottom surface of the photovoltaic module102. In some examples, the top surface900of the rail104is substantially flat/planar, while in other examples, the top surface900has one or more bends, curves, undulations, protrusions, recesses, channels, etc. In an example, the top surface900lies within a top rail surface plane902. The top rail surface plane902defines a first side904and a second side906. The clamp340and the photovoltaic module102are disposed on the first side904of the top rail surface plane902. The head308and the channel206are disposed on the second side906of the top rail surface plane902.

The support structure320is disposed between the clamp340on a first side920of the support structure320and the top rail surface plane902on a second side922of the support structure320. In the illustrated example, the first side920of the support structure320may be in contact with and/or adjacent to the clamp340. In this example, the second side922of the support structure320may be spaced a distance apart from the top surface900of the rail104. In such an example, the second side922of the support structure320may not contact and/or engage the rail104, but, rather, may be supported the distance apart from the rail104by the bolt302(e.g., by receiving the bolt302therethrough).

The support structure320can position the clamp340at a first location930on the bolt302when the second end306of the bolt302is received within the rail104and the clamp340does not secure the one or more photovoltaic modules102to the rail. Indeed, in this example, the clamp340may be initially spaced a distance apart (e.g., above) the photovoltaic module102. As such, when the support structure320positions the clamp at the first location930, the photovoltaic module102can be moved with respect to the clamp340, such that the photovoltaic module102can be oriented/positioned as desired. It will be appreciated that the first location930illustrated inFIG. 9is not intended to be limiting. Rather, in other examples, the first location930can be located higher or lower along the bolt302than as illustrated. In these examples, the first location930represents a position in which the clamp340may not interfere with, contact, and/or secure the photovoltaic module102, such that the photovoltaic module102can be oriented/positioned as desired.

In the illustrated example, the first location930may be located a first distance932from the top rail surface plane902within which the top surface900of the rail104lies. In this example, the first distance932extends along a first distance axis934that is substantially parallel to the bolt axis310. The first distance932may be measured from the top rail surface plane902to a bottom surface936of the clamp340. In the illustrated example, the clamp340is disposed on the first side920of the top rail surface plane902when the clamp340is positioned at the first location930. The second end306of the bolt302is disposed to the second side922of the top rail surface plane902when the second end306of the bolt302is received within the rail104.

Turning toFIG. 10, the support structure320can position the clamp340at a second location950on the bolt302when the second end306of the bolt302is received within the rail104and the clamp340does secure the one or more photovoltaic modules102to the rail. In this example, the nut360can be tightened onto the bolt302, thus causing the nut360to move in a downward direction with respect to the bolt302towards the second end306of the bolt302and the head308. As the nut360is tightened, the clamp340(and, thus, the support structure320) is moved from the first location930(e.g., illustrated inFIG. 9) on the bolt302downwardly towards the second location950on the bolt302. The nut360can be tightened at least until the clamp340contacts/engages the photovoltaic module102. Once the clamp340contacts/engages the photovoltaic module102, the photovoltaic module102is secured and is limited from being inadvertently removed from the clamping apparatus300and the rail104.

In the illustrated example, the second location950may be located a second distance952from the top rail surface plane902within which the top surface900of the rail104lies. In this example, the second distance952extends along a second distance axis954that is substantially parallel to the bolt axis310. The second distance952may be measured from the top rail surface plane902to the bottom surface936of the clamp340. In such an example, the clamp340is disposed to the first side920of the top rail surface plane902when the clamp340is positioned at the second location950, the first distance932is different than the second distance952. In the illustrated examples, the first distance932is greater than the second distance952.

The support structure320has a support structure thickness960corresponding to a third distance962. The third distance962is measured axially from a first end964(e.g., top end) of the support structure to a second end966(e.g., bottom end) of the support structure320. In an example, the third distance962extends along a support structure axis968that is substantially parallel to the bolt axis310. The third distance962may be less than the first distance932and less than the second distance952. In an example, the third distance962may be less than about one half (½) of the second distance952. In another example, the third distance962may be less than about one quarter (¼) of the second distance952.

Having the third distance962(e.g., corresponding to an axial length of the support structure320) be less than the second distance952is beneficial in a number of ways. First, the support structure320has a relatively short axial length (e.g., between the first end964and the second end966), thus reducing the cost of the support structure320(e.g., less material). Second, the support structure320can be positioned at a relatively large number of locations along the bolt302, such that the clamp340can be supported (e.g., by the support structure320) at a wide range of locations along the bolt302.

In the illustrated example, the second end966of the support structure320is separated a fourth distance980from the grounding device312. The support structure thickness960corresponding to the third distance962is less than the fourth distance980. As such, a gap, space, etc. exists between the second end966of the support structure320and the grounding device312and the second end306of the bolt302.

Turning toFIGS. 11 and 12, a top down view of the support structure320and the bolt302is illustrated. In an example, the support structure320comprises an expandable/compressible material, such as a gasket, for example. The support structure320defines the second bolt opening322into which the bolt302is received. Due to being comprised of an expandable/compressible material, the support structure320, and, thus, the second bolt opening322, is expandable between an unexpanded stated (e.g., illustrated inFIG. 11) and an expanded state (e.g., illustrated inFIG. 12).

As illustrated inFIG. 11, the second bolt opening322defines a first cross-sectional size1100in the unexpanded state. In this example, the bolt302defines a third cross-sectional size1104. In the unexpanded state, the second bolt opening322, defining the first cross-sectional size1100, is smaller than the bolt302. That is, the first cross-sectional size1100of the second bolt opening322in the unexpanded state is less than the third cross-sectional size1104of the bolt302. As such, when the support structure320is in the unexpanded state, the bolt302may not fit into the second bolt opening322.

Turning toFIG. 12, the support structure320can be expanded1106from the unexpanded state (e.g., illustrated inFIG. 11) to an expanded state (e.g., illustrated inFIG. 12). The expansion1106of the support structure320is illustrated schematically inFIG. 11(e.g., with arrowheads), as the expansion1106can occur in any number of ways. For example, the support structure320can be expanded1106by a pulling force, such as by a user/operator pulling the support structure320radially outwardly.

After the expansion1106, the second bolt opening322of the support structure320defines a second cross-sectional size1110in the expanded state. In this example, the first cross-sectional size110of the support structure320in the unexpanded state is less than the second cross-sectional size1110of the support structure320in the expanded state. In an example, the second cross-sectional size1110is larger/greater than the third cross-sectional size1104of the bolt302. Accordingly, as illustrated inFIG. 12, the bolt302can fit within and be received within the second bolt opening322when the second bolt opening322of the support structure320is in the expanded state. As such, the third cross-sectional size1104of the bolt302is larger than the first cross-sectional size1100and less than the second cross-sectional size1110.

The support structure320can therefore be compressed/expanded between the unexpanded state (e.g., illustrated inFIG. 11) and the expanded state (e.g., illustrated inFIG. 12). When the support structure320is expended to the expanded state, the second bolt opening322is sized to receive the bolt302. As such, the bolt302can be received within and passed through the second bolt opening322, such that the support structure320can be moved/adjusted along the bolt302. When the pulling/expanding force (e.g., expansion1106) is no longer provided to the support structure320, the support structure320can revert back towards the unexpanded state. However, after the bolt302is received through the second bolt opening322, the support structure320can radially compress onto the bolt302(e.g., as illustrated inFIGS. 9 and 10). When the support structure320has compressed onto the bolt302, the support structure320can radially surround and compress onto the bolt302, such that the support structure320contacts/engages and “grips” the bolt302.

When the support structure320radially compresses onto the bolt (e.g., contacts/engages, grips, etc.), the support structure320is limited from inadvertently moving (e.g., axially up/down, radially, etc.) with respect to the bolt302. Rather, for the support structure320to move (e.g., axially up/down, radially, etc.) with respect to the bolt302, a sufficient force can be applied, with the force being greater than the compressive force exerted by the support structure320onto the bolt302. In an example, this force could be applied by pushing/pulling the support structure320axially up/down the bolt302. In another example, this force could by applied by pushing/pulling the clamp340axially up/down the bolt302such that the clamp340acts upon the support structure320and causes the support structure320to move axially up/down the bolt302. In yet another example, this force could be applied by rotating the nut360with respect to the bolt302, causing the nut360to drive the clamp340axially downwardly, which thus causes the support structure320to move axially up/down the bolt302. Accordingly, due to the expansion/contraction of the support structure320, the support structure320can maintain a relative position with respect to the bolt302at least until it is desired to move the support structure320(e.g., as illustrated fromFIG. 9toFIG. 10, and/or as illustrated fromFIG. 14toFIG. 16, and/or as illustrated fromFIG. 17toFIG. 19).

Turning toFIG. 13, a second example clamping apparatus1300is illustrated. In this example, the second clamping apparatus1300comprises a second example support structure1302. The support structure1302comprises a first affixation1304that can affix the clamp340to the nut360when the second end306of the bolt302is received within the rail104and the clamp340does not secure the one or more photovoltaic modules102to the rail104. The first affixation1304comprises any number of materials. In some examples, the first affixation1304comprises an adhesive (e.g., glue, paste, cement, tape, etc.), a temporary weld (e.g., tack weld, etc.), a magnet, or other temporary fixation structure.

In this example, the first affixation1304is illustrated as being disposed on a top surface1306of the clamp340around the bolt opening342. Such a position is not intended to be limiting, however. Rather, in other examples, the first affixation1304could be disposed on the nut360(e.g., bottom surface of the nut360) instead of the top surface1306of the clamp340. In still other examples, the first affixation1304could be disposed on both of the top surface1306of the clamp340and the nut360. In these examples, the first affixation1304may be disposed between the nut360and the clamp340, such that the first affixation1304can affix the clamp340to the nut360.

Turning toFIG. 14, an example operation of the second clamping apparatus1300is illustrated. In this example, the support structure1302(e.g., the first affixation1304) can initially position the clamp340at the first location930on the bolt302. Due to the first affixation1304being positioned between and in contact with the clamp340and the nut360, the clamp340and the nut360are initially temporarily fixed to each other. With the clamp340fixed to the nut360, the clamp340is limited from moving towards the second end306of the bolt302when the nut360does not move towards the second end306. That is, when the clamp340and the nut360are initially fixed to each other with the first affixation1304, the clamp340does not move independently of the nut360, such that the clamp340remains at the first location930.

Turning toFIG. 15, the nut360can be rotated, thus causing the clamp340and the nut360to detach from each other. For example, as illustrated inFIGS. 4 and 5, the bolt opening342has a generally matching shape as the bolt302. As such, the clamp340is limited from rotating with respect to the bolt302. Instead, movement of the clamp340with respect to the bolt302is substantially limited to the axial (e.g., up and down) direction, with limited to no rotational movement of the clamp340with respect to the bolt302. As such, when the nut360engages the threads of the bolt302, the nut360can be rotated with respect to the bolt302. Due to the nut360and the clamp340being fixed with the first affixation1304, rotation of the nut360can cause the first affixation1304to fracture/break. More particularly, since the clamp340is limited from rotating with respect to the bolt302, when the nut360is rotated with respect to the bolt302, the attachment between the nut360and the clamp340(e.g., the first affixation1304) is broken, such that the nut360is no longer attached/affixed to the clamp340. Accordingly, the nut360can threadingly engage the bolt302by being rotated such that the nut360moves axially downwardly with respect to the bolt302towards the second end306of the bolt302. The clamp340, now no longer affixed to the nut360, can move downwardly (while not rotating) with respect to the bolt302towards the second end306.

The nut360can continue to be rotated at least until the clamp340is at the second location950on the bolt302when the second end306of the bolt302is received within the rail104and the clamp340does secure the one or more photovoltaic modules102to the rail. The nut360can be tightened onto the bolt302, thus causing the clamp340to move from the first location930(e.g., illustrated inFIG. 14) downwardly towards the second location950on the bolt302. The nut360can be tightened at least until the clamp340contacts/engages the photovoltaic module102. Once the clamp340contacts/engages the photovoltaic module102, the photovoltaic module102is secured and is limited from being inadvertently removed from the clamping apparatus300and the rail104.

Turning toFIG. 16, a second example nut1600is illustrated. The nut1600can be affixed to the clamp340with the first affixation1304. In addition to the first affixation1304, the support structure1302comprises a second affixation1602that affixes the nut1600to a location on the bolt302to position the clamp340at the first location930. The second affixation1602comprises a wall, cover, surface, ceiling, adhesive (e.g., glue, tape, etc.), or any similar structure that covers an opening in the nut1600through which the bolt302is received and, at least temporarily, restricts passage of the bolt302through the nut1600at least until a sufficient force between the bolt302and the nut1600causes rupture of the second affixation1602.

Turning toFIGS. 17 and 18, a third clamping apparatus1700is illustrated. The third clamping apparatus1700comprises the nut1600affixed to the clamp340. In an example, when the nut1600is received onto the bolt302, the first end304of the bolt302contacts/abuts the second affixation1602. The second affixation1602comprises a feature (e.g., wall, cover, surface, ceiling, adhesive, glue, tape, etc.) that, when in a first state (e.g., as illustrated inFIG. 17), restricts the nut1600from being threaded onto the bolt302past a first threaded distance1800(e.g., as illustrated inFIG. 18). The first threaded distance1800extends along a first threaded distance axis1802that is substantially parallel to the bolt axis310and is measured from a surface1804(e.g., a bottom surface) of the nut1600to the first end304of the bolt302. In such an example, the nut1600is limited from being further rotated onto the bolt302such that the nut1600is limited from moving downwardly. As such, in this first state, the support structure1302can position the clamp340at the first location930on the bolt302.

Turning toFIG. 19, in a second state, the second affixation1602does not restrict the nut1600from being threaded onto the bolt302past the first threaded distance1800. In this example, the nut1600can be rotated from the first state (e.g., as illustrated inFIG. 17) to the second state. Rotation of the nut1600causes a force to be applied onto the second affixation1602by the first end304of the bolt302. In particular, the nut1600is rotated with a sufficient amount of rotational force to cause the nut1600to move downwardly along the bolt302. As the nut1600moves downwardly, the first end304can push through the second affixation1602, causing the second affixation1602to rupture1900.

Once the second affixation1602is ruptured, the nut1600can continue to be rotated at least until the clamp340is at the second location950on the bolt302when the second end306of the bolt302is received within the rail104and the clamp340does secure the one or more photovoltaic modules102to the rail. The nut1600can be tightened onto the bolt302, thus causing the clamp340to move from the first location930(e.g., illustrated inFIG. 17) downwardly towards the second location950on the bolt302. The nut1600can be tightened at least until the clamp340contacts/engages the photovoltaic module102. Once the clamp340contacts/engages the photovoltaic module102, the photovoltaic module102is secured and is limited from being inadvertently removed from the clamping apparatus300and the rail104.

Turning toFIG. 20, another example of the clamping apparatus300is illustrated. The clamping apparatus300can include the bolt302, the grounding device312, the clamp340, and the nut360. In this example, the clamping apparatus300includes a support structure2000. In contrast to the previous examples in which a support structure was disposed below the clamp340(e.g., as illustrated inFIGS. 9 and 10) or above the clamp340(e.g., as illustrated inFIG. 13), in this example, the support structure2000can be disposed at least partially within the clamp340.

The support structure2000can be positioned within the bolt opening342of the clamp340. The support structure2000has a cross-sectional size that is less than a cross-sectional size of the bolt opening342, such that the support structure2000is received within the bolt opening342. In the example ofFIG. 20, the support structure2000is positioned within the bolt opening342of clamp340prior to the support structure2000and/or the clamp340being attached to the bolt302. In other examples, the support structure2000can first be attached to the bolt302, such as by receiving the bolt302through a second bolt opening2002. Once the support structure2000is attached to the bolt302, the clamp340can then be inserted over and/or surrounding the support structure2000. In operation, the clamp340can be supported at a location (e.g., the first location930, the second location950, etc.) axially along the bolt302due to the support structure2000being disposed radially between the bolt302and the clamp340.

Turning toFIG. 21, a top down view of an example of the support structure2000is illustrated. In this example, the support structure2000defines the second bolt opening2002. In an example, the support structure2000has a cross-sectional shape that substantially matches a cross-sectional shape of the bolt302and/or a cross-sectional shape of the bolt opening342of the clamp340. For example, the support structure2000comprises a non-linear portion2100and a linear portion2102. In this example, the non-linear portion2100defines a rounded, circular shape, while the linear portion2102defines a straight side of the support structure2000. The support structure2000is therefore hollow and comprises a wall that is shaped to have the non-linear portion2100and the linear portion2102. The support structure2000comprises any number of materials, some of which may include the materials of the support structure320. For example, the support structure2000comprises elastomeric materials, neoprene materials, or the like. In such an example, the support structure2000has at least some degree of compressibility/flexibility, such that the support structure2000can be deformed/compressed/expanded/etc. in response to one or more forces.

Turning toFIG. 23, a top down view of the support structure2000attached to the bolt302and received within the bolt opening342of the clamp340is illustrated. In this example, the support structure2000can support the clamp340at a location (e.g., the first location930, the second location950, etc.) along the bolt302. The support structure2000can receive the bolt302within the second bolt opening2002. With the support structure2000received onto the bolt302, the clamp340can be inserted onto the support structure2000. For example, the bolt opening342of the clamp340can be moved so as to receive the support structure2000therein. In such an example, the non-linear portion2100of the support structure2000can be aligned with non-linear portions of the bolt opening342and the bolt302. Similarly, the linear portions2102of the support structure2000can be aligned with linear portions of the bolt opening342and the bolt302.

The support structure2000can therefore be positioned between the clamp340and the bolt302. In this example, the support structure2000is radially received between the clamp340and the bolt302, with the support structure2000radially surrounding the bolt302, while the clamp340radially surrounds the support structure2000. That is, an outer radial side of the support structure2000contacts/engages the clamp340while an inner radial side of the support structure2000contacts/engages the bolt302. The support structure2000can therefore contact/engage both the clamp340and the bolt302. This contact/engagement between the support structure2000and the clamp340can support the clamp340at the desired location, with the clamp340being limited from moving axially up/down. Further, due to the substantially matching shape of the bolt opening342, the support structure2000and the bolt302, the clamp340(and, thus, the support structure2000) can be rotatably attached (e.g., see712) to the bolt302in a similar manner as described inFIGS. 7 and 8.

FIG. 23illustrates a cross-sectional view of the support structure2000, the clamp340, and the bolt302taken along lines23-23inFIG. 22. As illustrated, the support structure can support the clamp340at a location along the bolt302. The support structure2000may have a support structure thickness2300that corresponds to a third distance2302measured from a first end2304of the support structure2000to a second end2306of the support structure2000. In an example, the third distance2302extends along a support structure axis2308that is substantially parallel to the bolt axis310and is less than the first distance932and the second distance952. In this example, the third distance2302(e.g., the support structure thickness2300) of the support structure2000is substantially equal to a clamp thickness of the clamp340. That is, the first end2304of the support structure2000is substantially planar with respect to a top surface of the clamp340. The second end2306of the support structure2000is substantially planar with respect to a bottom surface of the clamp340. As such, the support structure2000is substantially limited from contacting the nut360(e.g., at the first end2304of the support structure2000) and/or the photovoltaic module102(e.g., at the second end2306of the support structure2000).

In operation, the support structure2000can support the clamp340at a location along the bolt302. In this example, the support structure2000and the clamp340are support at a same axial location along the bolt302. When a user/operator desires to move the clamp340, such as to move the clamp340into engagement with the photovoltaic module102, the user/operator can tighten the nut360. Tightening of the nut360can cause the clamp340and the support structure2000to move along a movement direction2310downwardly towards the photovoltaic module102. In such an example, the force applied by the nut360is at least enough to overcome a compressive force exerted by the support structure2000onto the bolt302, such that tightening of the nut360onto the bolt302can cause the support structure2000and the clamp340to move in the movement direction2310(e.g., downwardly).

In the aforementioned examples illustrated and described with respect toFIGS. 1 to 23, the clamping apparatus (e.g.,300,1300,1700) may be assembled prior to coupling it to the rail and/or it may be assembled as part of the act of coupling the clamping apparatus to the rail. For example, in one embodiment, the clamping apparatus is preassembled such that the bolt, support structure, clamp, and/or the nut are coupled together (e.g., fastened together) prior to the clamping apparatus being coupled to the rail (e.g., in a factory and/or at an installation site). In this way, the clamping apparatus is one unit prior to assembly with the rail. However, in another embodiment, coupling the clamping apparatus to the rail may comprise assembling the clamping apparatus on the rail. For example, a second end of the bolt may be inserted into a channel of the rail, and the rail may be positioned/oriented as desired. Subsequently, the support structure may be associated with the bolt, a clamp may be placed onto the bolt via a bolt opening of the clamp, and a nut may be secured to the bolt to hold the support structure and clamp in place.

Typically, the support structure is configured to maintain a relative orientation of the clamping apparatus and the rail (e.g., such that angle between the clamping apparatus and a top edge of the rail is substantially ninety degrees). Moreover, in an embodiment, the support structure may be slightly compressed as part of the preassembly such that a degree of pressure is applied to the rail. Such pressure may further assist in maintaining a position of the clamping apparatus relative to the rail (e.g., such that the clamping apparatus does not slide along the channel). Thus, the support structure may be utilized to reduce slippage of the clamping apparatus when (an edge of) a module is positioned between the rail and the clamp of the clamping apparatus, for example.

As described above, in some embodiments, the clamp and/or the bolt may comprise features that further aid in the installation of the photovoltaic modules and/or in securing the photovoltaic module(s) to the rail. For example, in one embodiment, the bolt may comprise a shaft having a non-cylindrical portion and the clamp may comprise a corresponding (e.g., similarly shaped), non-cylindrical opening through which the non-cylindrical portion of the bolt can be inserted. In this way, rotation of the bolt relative to the clamp is reduced (e.g., to reduce the possibility of the bolt being turned in such a manner that it can slip and/or rotate out of the channel). Moreover, the clamp may comprise tabs that abut a side-edge of the photovoltaic modules to further reduce the possibility of the clamp rotating.

Once the rail is preassembled at (e.g., which includes coupling the clamping apparatus to the rail), the preassembled rail may be shipped for assembly. In this way, the rail may be shipped from the factory with the clamping apparatuses preinstalled at specified locations to reduce installation time on site, for example. To complete the installation onsite, the installer therefore merely attaches the rails to an installation site (e.g., a roof) inserts one or more modules into the space between the top edge of the rail and the clamp (e.g., as established by the support structure), secures the module by tightening a nut of the respective clamping apparatuses (e.g., already installed on the rail), and connects wiring of photovoltaic module(s) to a power grid and/or power consumption device, for example.

It may be appreciated that the words “example” and/or “exemplary” are used herein to mean serving as an example, instance, or illustration. Any aspect, design, etc. described herein as “example” and/or “exemplary” is not necessarily to be construed as advantageous over other aspects, designs, etc. Rather, use of these terms is intended to present concepts in a concrete fashion. As used in this application, the term “or” is intended to mean an inclusive “or” rather than an exclusive “or”. That is, unless specified otherwise, or clear from context, “X employs A or B” is intended to mean any of the natural inclusive permutations. That is, if X employs A; X employs B; or X employs both A and B, then “X employs A or B” is satisfied under any of the foregoing instances. In addition, the articles “a” and “an” as used in this application and the appended claims may generally be construed to mean “one or more” unless specified otherwise or clear from context to be directed to a singular form. Also, at least one of A and B or the like generally means A or B or both A and B.