CLAMPING ASSEMBLY FOR MOUNTING SOLAR PANEL MODULES

A clamp assembly for securing a solar panel module includes a clamp base, a clip movably connected to the clamp base, and a biasing fastener extending through the clamp base and the clip. The biasing fastener is configured to bias the clip from the clamp base.

BACKGROUND

The solar industry is experiencing rapid growth on a global scale, driving an increasing demand for effective and reliable mounting systems to secure solar panel modules (also referred to as PVs, photovoltaic modules, etc.) to various structures, such as roofs or other surfaces. Although there is a wide range of existing mounting solutions, there remains a strong desire to simplify the complexity and improve the efficiency of these systems while ensuring they maintain their essential anchoring integrity. With solar energy playing a crucial role in the shift toward sustainable energy, the development of more advanced, user-friendly, and robust mounting equipment is needed.

A significant number of solar panel modules are installed on rooftops, which presents unique challenges and risks. The elevated location increases the danger of falls and potential injury to the individuals tasked with installing the mounting equipment. Moreover, the complexity and variety of existing mounting systems often require installers to carry multiple tools up and down ladders and across rooftops, complicating the installation process and increasing the risk of accidents. Given these challenges, there is a pressing need for an improved mounting system.

DETAILED DESCRIPTION

This application relates to a clamping assembly for mounting solar panel modules to a mounting surface of a platform such as a rooftop.

In an embodiment, a clamp assembly may attach pivotally to a rail of a solar array mounting system to clamp onto a return flange of a frame of a solar panel module. The clamp assembly may include a clamp base and a clip movably connected to the clamp base. The clip may be fastened to the clamp base via a biasing fastener, such that the clip is movable in a first direction away from the clamp base, as well as slidably movable in a second direction that is a longitudinal direction relative to the clamp base.

In an embodiment, a method of using the clamp assembly may include the following operations. Upon placing a solar panel module frame on the clamp base, the clip may be: 1) pulled in the first direction away from the clamp base along the axis of the biasing fastener holding the clip to the clamp base, 2) rotated about the axis of the fastener and/or slid along the clamp base (via the clamp opening such as a slotted aperture therethrough) in the longitudinal direction, and 3) returned toward the clamp base (e.g., via a spring bias and/or threaded means, etc.) to clamp against the inner surface of the return flange of the frame of the solar panel module.

In an embodiment, the clamp base of the clamp assembly may be formed of folded sheet metal, for example. Other suitable materials and means of formation are within the scope of this disclosure, such as a molded plastic or other material, assuming the requisite strength and durability characteristics are met. Nevertheless, in an embodiment, the clamp base may include a panel flange support wall, a first clamp sidewall, and a second clamp sidewall, where the first clamp sidewall and the second clamp sidewall are spaced apart sufficiently to accommodate a rail (e.g., a rail for mounting solar panel array modules) therebetween. The first and the second clamp sidewalls may extend away from and transversely to the panel flange support wall to which the clip is connected. A mounting opening may be formed in the corresponding respective ends of each of the first and second clamp sidewalls such that the mounting openings are coaxial. Further, the first and second clamp sidewalls extend beyond a length of the panel support wall to form a channel therebetween. The channel is sized to accommodate the width of the upper portion of the rail to allow the first and second clamp sidewalls to partially straddle the rail, whereby a pivoting fastener (e.g., a clevis pin) may be inserted through the mounting openings and the rail (forming a pivot joint) to connect the clamp base to the rail. In an embodiment, the mounting openings are aligned laterally to be horizontally positioned when installed on the rail.

The clamp base may further include inwardly-extending, tapered flanges formed, respectively, at a distal edges of the first and second sides, opposite the intersection of the first and second clamp sidewalls with the panel flange support wall. Moreover, the tapered flanges may be disposed on respective ends of the clamp base, opposite the ends in which the mounting openings are located. The tapered flanges may be tapered gradually increasing inwardly to help the clamp assembly engage sidewalls of the rail when mounted on the rail and rotated against the rail. An advantage of the tapered flange may include reducing a tendency for the clamp assembly to wobble on the rail.

In an embodiment, the panel flange support wall of the clamp base may have one or more clamp openings (such as slotted apertures through the thickness direction thereof) such that the biasing fastener (such as a flanged bolt or another like fastener) may be inserted and slidably accommodated therein to connect the clamp base and the clip.

In an embodiment, the clamp base may further include a panel support ledge that extends from and transversely to the panel flange support wall of the clamp base. The panel support ledge is positioned to abut an outside wall of the frame of a solar panel module during installation thereof. As such, the panel support ledge extends away from the panel flange support wall in a direction opposite to the direction of extension of the first and second sidewalls. Additionally, a width direction of the panel support ledge extends in a plane that is orthogonal to respective planes extending through the first and second sidewalls. In an embodiment, the panel support ledge extends at an angle ranging from approximately 25 to 100 degrees, or more, relative to the panel flange support wall of the clamp base, but other angles are also contemplated.

The clamp base may further include a pivot restraining feature formed between the location of the panel support ledge and the location of the mounting openings through the first and second sidewalls. In an embodiment, the pivot restraining feature may include one or more protrusions from one or both of the first and second sidewalls, protruding inward to prevent the clamp base from rotating on the rail beyond a desired stopping point, for example, to prevent a clamped solar panel module from contacting (i.e., forcefully or otherwise) the rail, and/or to limit the amount of rotation of the clamp base and clamped solar panel module to remain in a vertical position. Thus, the stress of the rotational movement of a solar panel module on the rail and mounting structure is minimized.

In an embodiment, the one or more protrusions of the pivot restraining feature may include an inward extending flange bent or otherwise formed with or incorporated into the first and/or second sidewalls. Each of the one or more protrusions may include a vertex point, oriented to interfere with the rotational trajectory of the clamp base about the pivot axis by engagement with an upper wall of the rail. Thus, rotation may be stopped via contact between the horizontal vertex point and the surface of the rail. While the specific shape of the protrusion may vary, in an embodiment as shown, each of the one or more protrusions may be defined as an elongated flange that extends inwardly tapering from one or both ends of the elongation direction thereof, forming a stopping point. In an embodiment, the taper of the elongated flange tapers such that the clamp base would engage a sidewall of the rail in an increasing amount of abutment to slow the engagement and minimize flexion on the pivot joint. In an embodiment, the pivot restraining feature is configured to engage the top surface of the rail when the clamp base is rotated to an upright position that is about 90 degrees (between 80-110) relative to the upper wall of the rail.

As mentioned above, the clip may be formed as an elongated body defined, at least in part by a length dimension, a width dimension, and a thickness dimension. In an embodiment, the clip may further have a clip opening through the thickness dimension thereof. The clip opening may be sized to allow passage of the bolt to connect the clip to the panel support wall of the clamp base. In an embodiment, the clip opening may be threaded. Thus, the biasing fastener such as a bolt may be threaded therethrough such that the clip may function similarly to a “nut” when threaded on the biasing fastener. However, it is conceivable that other connection and tightening means are possible.

Furthermore, in an embodiment, the biasing fastener may have a flanged head and may be positioned such that the flanged head is disposed between the first and second clamp sidewalls of the clamp base, adjacent to the panel support wall of the clamp base. A spring (e.g., a coil spring, a helical spring, a conical spring, etc.) may be disposed between the flanged head of the biasing fastener and an inner-facing surface of the panel support wall of the clamp base. Such an arrangement may bias the clip against the clamp base when the bolt is at least partially threaded into the hole of the clip.

In an embodiment, the clip may further include first and second tabs folded at opposing sides of the clip (in the width dimension, corresponding with the width direction of the clamp base). The folded tabs extend away from the clip and, when connected to the clamp base, the tabs extend over the first and second sidewalls of the clamp base to prevent rotation of the clip. For example, in an embodiment, the tabs may be located at opposite corners at one end of the clip. Further, when clamping, the bolt is tightened and, due to the biased spring, the tabs further facilitate maintaining the clip in place until the tabs are fully engaged against the clamp base. In contrast, when the bolt is loose, the clip may still be rotated when the clip is pulled away from the clamp base.

FIG.1illustrates an isometric view of a clamp assembly100connected to a rail R, according to an embodiment of this disclosure. Referring toFIG.1, the clamp assembly100may include a clamp base102and a clip104. The clamp assembly100is configured to be installed on a rail R, which is part of a mounting system for securing solar panel modules or similar equipment. The clamp assembly100is configured to be pivotally connected to the rail R, allowing the clamp assembly100to rotate or adjust an angle between the clamp assembly100and the rail R. Such a pivotal connection is achieved through a pivoting fastener106, which serves as the axis around which the clamp assembly100may rotate relative to the rail R.

The pivoting fastener106may be selected from various types of hardware, including, but not limited to, a pin, clevis pin, dowel, rod, bolt, or screw. In the embodiment illustrated inFIG.1, the pivoting fastener106may be a clevis pin. The clevis pin is chosen for its practicality in this context, as the clevis pin simplifies the installation process by allowing easy insertion and removal while providing a reliable and sturdy pivot point.

The clip104may be operatively connected to the clamp base102in such a way that the clip104may slide along the longitudinal direction132-132′ of the clamp base102. This sliding mechanism allows for adjustments along the length of the clamp base102. Additionally, the clip104is configured to rotate within a range of at least 0 to 180 degrees relative to the upper surface of the clamp base102. The rotational capability allows the clip104to pivot and align properly with the return flange of a frame of a solar panel module (though not depicted inFIG.1, details of the return flange of a frame of a solar panel module are described in other parts of this disclosure) during installation. Once the clip104is appropriately rotated and slid into a proper position, the clip104may be fixed in place by advancing a biasing fastener108. The biasing fastener108may be implemented using various types of mechanical fasteners, including, but not limited to, a pin, clevis pin, dowel, rod, bolt, or screw.

As described herein, the clip104may be affixed to the clamp base102through the use of the biasing fastener108. For instance, in an embodiment, the biasing fastener108may have a flanged head110and may be positioned such that the flanged head110is disposed between the first and second clamp sidewalls of the clamp base102, adjacent to the panel support wall of the clamp base102.

The clip may include one or more biasing components configured to apply a force to the clip when manually manipulated away from the clamp base. For instance, the biasing components may include a spring112and a washer114incorporated into the biasing fastener108. The spring112(e.g., a coil spring, a helical spring, a conical spring, etc.) may be disposed between the flanged head of the biasing fastener and an inner-facing surface of the panel support wall of the clamp base102, to bias the clip104against the clamp base102when the biasing fastener108is at least partially threaded into the clip opening of the clip104. The inclusion of the spring112allows the clip104to be biased/rotated with respect to the clamp base102, applying a constant force that keeps the clip104in close proximity to the clamp base102, and allowing the clip104to be manually pulled away when necessary. Once the clip104is rotated and positioned properly onto the return flange of the frame of the solar panel module, the spring112helps the clip104to be drawn back toward the clamp base102, ready to be fastened into place.

The clip104may be configured with one or more tabs on both sides, such as a first tab116aand a second tab116b(only the first tab116ais visible in the view ofFIG.1, while additional details of the second tab116bare shown inFIG.3). When the clip104is engaged with the clamp base102, the first tab116aon one side and the second tab116bon the opposite side work together to restrict axial rotation of the clip104around the axis of the biasing fastener108. On the other hand, when the clip104is pulled upward from the clamp base102, the clip104becomes capable of rotating freely up to 360 or more, depending on the required rotational freedom.

The clamp base102may further include a first tapered flange130aand a second tapered flange130b. The tapered flanges130aand130bare configured to match the configuration (such as the sizes, the shapes, the angles, or the like) of the first and second beveled sidewalls124aand124bof the rail R. For example, the taper angles of the first and second tapered flanges130aand130bmay be configured to correspond with the inclination of the first and second beveled sidewalls124aand124b, respectively.

The rail R may be configured to complement and fit features of the clamp assembly100. For instance, the rail R may include an upper wall122flanked by two sidewalls, namely a first beveled sidewall124aand a second beveled sidewall124b. The beveled sidewalls124aand124bmay extend outwardly from the upper wall122and slope downwardly in a direction transverse to the upper wall122. In such a configuration, the first beveled sidewall124atransitions into a first rail base126a, a portion of which may be substantially parallel to the upper wall122, creating a flat surface. Similarly, the second beveled sidewall124btransitions to form a second rail base126b, which also has a portion that is substantially parallel to the upper wall122, providing a flat surface.

Moreover, the first rail base126amay include a first upturned flange128a, which, in turn, forms a first trough134athat extends along the longitudinal direction of the rail R. Similarly, the second rail base126bmay include a second upturned flange128b, creating a second trough134b, which also extends longitudinally along the rail R. These troughs134aand134bserve a function by helping to channel or divert water away from the solar panel array, thereby protecting the system from potential water damage.

The inclusion of the first upturned flange128aalso provides a clearance between a distal edge and the roof membrane, even if the rail R comes into contact with the membrane. Such a configuration helps prevent any direct pressure or abrasion on the roof membrane, reducing the risk of damage. The second upturned flange128bsimilarly offers a clearance, such that both sides of the rail R are properly spaced from the roof membrane.

FIGS.2A-2Cillustrate the clamp base102from various angles, providing detailed views of the structure of the clamp base102, according to an embodiment of this disclosure.FIG.2Aillustrates an isometric view of the clamp base102, as depicted inFIG.1, according to an embodiment of this disclosure. Referring toFIG.2A, the clamp base102may include a panel flange support wall208and two clamp sidewalls210aand210b. The panel flange support wall208forms the upper surface of the clamp base102.

The two clamp sidewalls, i.e., a first clamp sidewall210aand a second clamp sidewall210b, may extend downward from opposite edges of the panel flange support wall208. The first clamp sidewall210aand the second clamp sidewall210bare spaced apart sufficiently to accommodate the rail R therebetween. The first and the second clamp sidewalls210aand210bmay extend away from and transversely to the panel flange support wall208to which the clip104is connected.

Two mounting openings222aand222bmay be formed in corresponding respective ends of each of the first and second clamp sidewalls210aand210b, such that the mounting openings222aand222bare coaxial. In an embodiment, the mounting openings222aand222bare aligned laterally to be horizontally positioned when installed on the rail.

Further, the first and second clamp sidewalls210aand210bextend beyond the length of the panel support wall208to form a channel therebetween. The channel is sized to accommodate the width of the upper portion of the rail R to allow the first and second clamp sidewalls210aand210bto partially straddle the rail R, whereby the pivoting fastener106(e.g., a clevis pin) may be inserted through the mounting openings222aand222band the rail R (forming a pivot joint) to connect the clamp base102to the rail R.

The clamp base102may include one or more tapered flanges, such as the first tapered flange130aand the second tapered flange130b, which play a role in securing the engagement between the clamp base102and the rail R. For instance, the first tapered flange130aextends inwardly from the first clamp sidewall210a, while the second tapered flange130bextends inwardly from the second clamp sidewall210b. The first and the second tapered flanges130aand130bmay be tapered gradually, increasing inwardly to allow the clamp assembly100to engage the beveled sidewalls of the rail R when mounted on the rail T and rotated against the rail R. The first and second tapered flanges130aand130bare configured to interlock with the corresponding beveled sidewalls of the rail R, creating a connection when the clamp base102is pivoted into a proper position.

It should be noted that while the shapes and dimensions of the first and second tapered flanges130aand130bare exemplary in the described embodiments, they are not restrictive. Depending on specific implementation requirements, the angles and dimensions of the tapered flanges may be adjusted to optimize the engagement between the clamp base102and the rail R.

The panel flange support wall208may include one or more clamp openings, such as a first clamp opening212(1) and a second clamp opening212(2), configured to facilitate the attachment and movement of the clip104. The first clamp opening212(1) and the second clamp opening212(2) may take various shapes depending on the actual requirements, including circular, rectangular, elliptical, triangular, hexagonal, slotted, or other custom shapes. In the embodiment depicted inFIG.2A, the first clamp opening212(1) and the second clamp opening212(2) are slotted openings. The slotted shape is configured to provide flexibility in the positioning and adjustment of the clip104. By being oriented in the longitudinal direction132-132′ of the clamp base102, the slotted openings allow the clip104to pivot and slide along the length of the clamp base102, facilitating alignment and attachment between the clip104and the clamp base102.

Additionally, the clamp base102may further include a panel support ledge214extending from and transversely to the panel flange support wall208of the clamp base102. The panel support ledge214is positioned to abut an outside wall of the frame of a solar panel module during installation. As such, the panel support ledge214extends away from the panel flange support wall208in a direction opposite to the direction of extension of the first and second sidewalls210aand210b. Additionally, a width direction of the panel support ledge214extends in a plane that is orthogonal to respective planes extending through the first and second sidewalls210aand210b. In an embodiment, the panel support ledge214extends at an angle ranging, e.g., from 25 to 100 degrees, or more, relative to the panel flange support wall208of the clamp base.

The panel support ledge214is configured to enhance the overall stability and support of the solar panel module during installation. For instance, one end of the upper surface of the clamp base102may extend upwards from the main body of the clamp base102to form the panel support ledge214. The panel support ledge214is configured to provide support to the solar panel module.

The clamp base102may further include pivot restraining features configured to limit the amount of rotation between the clamp assembly100and the rail R. For instance, the pivot restraining features may include a first protrusion216a(not shown inFIG.2A, but illustrated inFIG.2C) and a second protrusion216b, configured to engage with rail R. The first protrusion216amay extend inwardly from an edge of the first clamp sidewall210a, while the second protrusion216bmay extend inwardly from an edge of the second clamp sidewall210b. The first protrusion216ais positioned between the panel support ledge214and the first mounting opening222a(not shown inFIG.2A, but illustrated inFIG.2C), while the second protrusion216bis similarly located between the panel support ledge214and the second mounting opening222bon the opposite side.

FIG.2Billustrates another isometric view of the clamp base102, as depicted inFIG.1, according to an embodiment of this disclosure.FIG.2Cillustrates yet another isometric view of the clamp base102, as depicted inFIG.1, according to an embodiment of this disclosure. InFIG.2BandFIG.2C, the same reference numbers are used to indicate the same elements as shown inFIG.2A, allowing for easy correlation between the figures.

Referring toFIG.2C, the first protrusion216amay include a first tapered portion218a, while the second protrusion216bmay include a second tapered portion218b. The first tapered portion218aand the second tapered portion218bare shaped to properly engage with the first beveled sidewall124aand the second beveled sidewall124bof the rail R, respectively. Such engagement may occur when the clamp base102is pivoted to approximately 90 degrees relative to the upper wall122of the rail R, as illustrated inFIG.1. Each of the first and the second protrusions216aand216bmay include a vertex point, oriented to interfere with the rotational trajectory of the clamp base102about the pivot axis by engagement with the upper wall122of the rail R. Thus, the rotation may be stopped via contact between the horizontal vertex point and the surface of the rail R. While the specific shape of the first and the second protrusions216aand216bmay vary, in an embodiment as shown, each of the first and the second protrusions216aand216bmay be defined as an elongated flange that extends inwardly tapering from one or both ends of the elongation direction of the clamp base102, forming a stopping point. In an embodiment, the taper of the elongated flange tapers such that the clamp base102would engage a beveled sidewall of the rail R in an increasing amount of abutment to slow the engagement and minimize flexion on the pivot joint. In an embodiment, the pivot restraining feature is configured to engage the top surface of the rail R when the clamp base102is rotated to an upright position that is about 90 degrees (e.g., between 80-110) relative to the upper wall122of the rail R.

Further, the first protrusion216amay be configured with a first abutment220a, and the second protrusion216bmay be configured with a second abutment220b. The first abutment220aand the second abutment220b, also referred to as vertex points, are configured to limit the rotational movement between the clamp assembly100and the rail R. For instance, the first abutment220aand the second abutment220bare configured to engage with the rail R in such a way that the first abutment220aand the second abutment220bmay restrict the clamp base102from rotating beyond a predetermined angle. For example, the first abutment220aand the second abutment220bmay be formed at angles that are transverse to the longitudinal dimension132-132′ of the clamp base102. Additionally, the first abutment220aand the second abutment220bmay be oriented orthogonally relative to the first clamp sidewall210aand the second clamp sidewall210b, respectively.

FIG.3illustrates a bottom isometric view of the clip104depicted inFIG.1A, according to an embodiment of this disclosure. Referring toFIG.3, the clip104may be formed as an elongated component defined, at least in part, by a length dimension (x direction), a width dimension (y direction), and a thickness dimension (z direction). In an embodiment, the clip104may include a clip opening310through the thickness dimension thereof. The clip opening310may be sized to allow passage of the biasing fastener108to connect the clip104to the panel support wall208of the clamp base102. Example types of clip opening310may include but are not limited to holes, apertures, etc. In an embodiment, the clip opening310may be threaded. Thus, the biasing fastener108(such as a bolt) may be threaded therethrough such that the clip104may function similarly to a “nut” when threaded on the biasing fastener108. However, it is conceivable that other connection and tightening means are possible.

The clip104may include a front lip304and a back lip306. The front lip304may protrude downwardly along the −z direction from a first side of the body302of the clip104, while the back lip306may protrude downwardly along the −z direction from an opposing second side of the body302of the clip104.

The clip104may include one or more tabs, such as the first tab116aand the second tab116b, which extend downwardly along the −z direction from the back lip306and are positioned on opposite sides of the clip104to enhance stability and functionality. These tabs are folded at opposing sides of the clip104, corresponding to the width direction of the clamp base102. When the clip104is connected to the clamp base102, the first tab116aand the second tab116bextend over the first sidewall210aand the second sidewall210b, respectively, of the clamp base102, effectively preventing rotation of the clip104. In an embodiment, the first tab116aand the second tab116bmay be located at opposite corners at one end of the clip104.

During the clamping process, as the biasing fastener108is tightened, the spring112helps the first tab116aand the second tab116bto engage against the clamp base102, further stabilizing the clip104. Conversely, when the biasing fastener108is loosened, the clip104may be rotated when the clip104is pulled away from the clamp base102.

When the clip104is engaged with the clamp base102, the first tab116aon one side and the second tab116bon the opposite side work together to restrict axial rotation of the clip104around the axis of the biasing fastener108.

The clip104may further include one or more grips, such as a first grip (not visible inFIG.3) and a second grip312b. The first grip may extend upwards along the z direction from a third side of the body302of the clip104, while the second grip312bmay extend upwards along the z direction from an opposing fourth side of the body302of the clip104. The first grip and the second grip312bare configured to facilitate the installation process by providing a proper grasp point for the user.

In some embodiments, the second grip312bmay include one or more cavities, such as a first cavity314(1) and a second cavity314(2), which are configured to enhance manual control when handling the clip104. The first cavity314(1) and the second cavity314(2) not only improve grip but also help reduce the overall weight of the clip, thus facilitating convenient handling and installation. The first cavity314(1) and the second cavity314(2) may be configured as partial holes or through holes, depending on specific design requirements, such as the need for weight reduction, structural reinforcement, or ease of manufacturing. AlthoughFIG.3depicts two cavities, it should be noted that additional or fewer cavities could be incorporated based on the application.

FIG.4Aillustrates an expanded view of a solar panel module mounting system400before installation of a solar panel module, according to embodiments of this disclosure. Referring toFIG.4A, the mounting system400may include a plurality of rails, such as a first rail R1and a second rail R2. WhileFIG.4Adepicts two rails, it should be noted that the number of rails may be customized based on specific installation requirements, allowing for either fewer or additional rails to accommodate different solar panel configurations. The first rail R1and the second rail R2are configured to be positioned on a surface S of a roof or a platform. In addition, whileFIGS.4A-4Cshow an example solar panel module system400of which clamp assembly100is a component, clamp assembly100may be used in different solar panel module mounting systems and different environments without departing from the spirit and scope of the present disclosure.

Both the first rail R1and the second rail R2may extend in parallel along the x-direction. In addition to providing support for the solar panels, the first rail R1and the second rail R2are also configured to allow for the attachment of other components, such as ballast rails, clamps, and other structural elements, enhancing the overall versatility and adaptability of the mounting system400to meet various installation needs.

The mounting system400may further include a plurality of ballast rails positioned across the plurality of rails, such as a first ballast rail404(1), a second ballast rail404(2), a third ballast rail404(3), and a fourth ballast rail404(4). AlthoughFIG.4Aillustrates four ballast rails, it should be noted that the number of ballast rails may be adjusted based on specific requirements, allowing for either fewer or additional ballast rails as needed. The plurality of ballast rails are positioned to extend along the y-direction, which is perpendicular to the x-direction.

The first ballast rail404(1) and the second ballast rail404(2) may be paired together and attached to both the first rail R1and the second rail R2. Similarly, the third ballast rail404(3) and the fourth ballast rail404(4) may be paired and attached to the first rail R1and the second rail R2.

The mounting system400may further include a plurality of clamp assemblies, such as a first clamp assembly100(1), a second clamp assembly100(2), a third clamp assembly100(3), and a fourth clamp assembly100(4). AlthoughFIG.4Aillustrates four clamp assemblies, it should be noted that the number of clamp assemblies may be adjusted based on specific requirements, allowing for either fewer or additional clamp assemblies as needed.

The first clamp assembly100(1) and the second clamp assembly100(2) may be attached to the first rail R1, while the third clamp assembly100(3) and the fourth clamp assembly100(4) may be attached to the second rail R2. In some embodiments, the first clamp assembly100(1) and the third clamp assembly100(3) may be paired to support a solar panel module, while the second clamp assembly100(2) and the fourth clamp assembly100(4) may be paired to support another solar panel module.

In one embodiment, the first clamp assembly100(1) may be positioned along the longitudinal dimension of rail R1nearest the fourth ballast rail404(4), providing an anchoring point for a solar panel module. Similarly, the second clamp assembly100(2) may be attached to rail R1along the longitudinal dimension of the rail R1between the two pairs of ballast rails. On the opposite side, the third clamp assembly100(3) may be attached to rail R2along the longitudinal dimension of the rail R2nearest the fourth ballast rail404(4). The fourth clamp assembly100(4) may be attached to rail R2along the longitudinal dimension of the rail R2between the two pairs of ballast rails.

The mounting system400may further include a plurality of stanchions, such as a first stanchion402(1), a second stanchion402(2), a third stanchion402(3), and a fourth stanchion402(4). WhileFIG.4Adepicts four stanchions, it should be noted that the number of stanchions may be adapted based on specific installation needs, allowing for either fewer or additional stanchions as required.

In some embodiments, the first stanchion402(1), the second stanchion402(2), the third stanchion402(3), and the fourth stanchion402(4) may be positioned and attached at the “south end” of the mounting system400. The first stanchion402(1) and the second stanchion402(2) may be paired and attached to the first rail R1, while the third stanchion402(3) and the fourth stanchion402(4) may be paired and attached to the second rail R2. In one embodiment, the first stanchion402(1) may be positioned along the z-direction on the rail R1between the two pairs of ballast rails. Similarly, the second stanchion402(2) may be attached to the rail R1along the z-direction nearest the first ballast rail404(1). On the opposite side, the third stanchion402(3) may be attached to the rail R2along the z-direction between the two pairs of ballast rails. The fourth stanchion402(4) may be attached to the rail R2along the z-direction near the first ballast rail404(1).

The mounting system400may further include one or more pads, such as a first pad406(1), a second pad406(2), and a third pad406(3). WhileFIG.4Aillustrates three pads, the number of pads may be customized based on specific installation requirements, allowing for either fewer or additional pads as necessary. The first pad406(1), the second pad406(2), and the third pad406(3) are configured to protect the mounting surface S of a roof or other platforms where the mounting system400is installed.

The first pad406(1) may be positioned between the first rail R1and the mounting surface S, while the second pad406(2) and the third pad406(3) may be placed between the second rail R2and the mounting surface S.

FIG.4Billustrates a partial view of the solar panel module mounting system400depicted inFIG.4A, showing an intermediate stage of the installation process for the solar panel module408, according to embodiments of this disclosure. InFIG.4B, the mounting system400is rotated 180 degrees relative to the view presented inFIG.4A, offering an alternative perspective on the installation process.

Referring toFIG.4B, in the intermediate stage of the installation, the solar panel module408is attached to the mounting system400via a pair of clamp assemblies, that is, the first clamp assembly100(1) and the third clamp assembly100(3). The first clamp assembly100(1) is pivotally attached to the first rail R1, while the third clamp assembly100(3) is pivotally attached to the second rail R2. After the solar panel module408has been fastened to both the first clamp assembly100(1) and the third clamp assembly100(3), the solar panel module408may be rotated or pivoted downward via the first clamp assembly100(1) and the third clamp assembly100(3) along the direction indicated by arrow410towards a pair of stanchions, that is, the first stanchion402(1) and the third stanchion402(3).

FIG.4Cillustrates a partial view of the solar panel module mounting system400depicted inFIG.4A, showing the final stage of the installation process for the solar panel module408, according to embodiments of this disclosure. InFIG.4C, the mounting system400is presented from the same perspective as inFIG.4B, but rotated 180 degrees relative to the view shown inFIG.4A. As described herein, the solar panel module408is attached to the mounting system400via a pair of clamp assemblies, namely the first clamp assembly100(1) and the third clamp assembly100(3) (not shown inFIG.4C, but illustrated inFIGS.4A and4B).

Referring toFIG.4C, at this final stage of installation, the solar panel module408is shown pivoted or rotated downward into a finished position through the rotation of the first clamp assembly100(1) and the third clamp assembly100(3) along the direction504, where the solar panel module408rests upon a pair of stanchions, that is, the first stanchion402(1) and the third stanchion402(3). The first stanchion402(1) and the third stanchion402(3) are configured to provide support to the solar panel module408.

FIGS.5A-5Cprovide various views of the clamp assembly100along with the solar panel module408during various stages of the clamping process.FIG.5Aillustrates a side view of the clamp assembly100along with a frame502of the solar panel module408in a first stage of the installation process, according to an embodiment of this disclosure. Referring toFIG.5A, at this first stage, the clamp assembly100is connected to the rail R via a pivoting fastener106, which serves as the rotational axis, allowing the clamp assembly100to pivot relative to the rail R. Next, the clamp assembly100is rotated into an upright position, where the clamp assembly100is substantially perpendicular to the top surface of the rail R, thereby setting the stage for the subsequent installment of the solar panel module408. The clip104is attached to the clamp base102via a biasing fastener108.

The frame502of the solar panel module408may include a frame sidewall504and a return flange506. The frame sidewall504is configured to rest against the panel support ledge214. As described herein, the panel support ledge214is configured to provide additional support for the solar panel module408.

The panel support ledge214may extend at a right angle from the sidewall504of the solar panel module frame502. The panel support ledge214is configured to work with the clip104.

FIG.5Billustrates a side view of the clamp assembly100along with the frame of the solar panel module408during a second stage of the clamping process, according to embodiments of this disclosure. In this second stage, as depicted inFIG.5B, the clip104is pulled in the direction508away from the clamp base102along the axis of the fastener108. Such a movement allows the clip104to disengage from its initial position and provides the necessary clearance for further adjustment. Next, the clip104may be slid in a longitudinal direction510along the clamp base102, moving towards the return flange506of the solar panel frame502. This sliding action is guided through either the first clamp opening212(1) or the second clamp opening212(2) (not visible inFIG.5B, but shown inFIG.1andFIGS.2A-2C).

Alternatively, the clip104may be rotated instead of slid along the clamp base102, using the same clamp openings. As described herein, the first clamp opening212(1) and the second clamp opening212(2) may be configured as slotted apertures, which facilitate the movement, adjustment, and positioning of the clip104.

FIG.5Cillustrates a side view of the clamp assembly100along with the frame502of the solar panel module408during a third stage of the clamping process, according to embodiments of this disclosure. At this third stage, as shown inFIG.5C, the clip104is returned toward the clamp base102along direction508′, either through a spring bias mechanism, threaded engagement, or similar means. Such a motion allows the clip104to move back into position, allowing the clip104to exert clamping force on the return flange506of the frame502. Upon reaching the proper position, the clip104effectively clamps against the inner surface of the return flange506of the solar panel module408.

FIG.6illustrates a cross-sectional view of the clamp base102along with the rail R as seen from line A-A′ inFIG.5A, according to embodiments of this disclosure. Referring toFIG.6, the first protrusion216aincludes a first tapered portion218aand a first abutment220a, while the second protrusion216bfeatures a second tapered portion218band a second abutment220b. The first tapered portion218ais configured to engage with the first beveled sidewall124aof the rail R, while the second tapered portion218bis configured to engage with the second beveled sidewall124bof the rail R. The first abutment220aand the second abutment220bare configured to engage with the upper wall122of the rail R.

The first tapered portion218aand the second tapered portion218bare shaped to properly engage with the first beveled sidewall124aand the second beveled sidewall124bof the rail R, respectively. Such engagement may occur when the clamp base102is pivoted to approximately 90 degrees relative to the upper wall122of the rail R, as illustrated inFIG.5A. Each of the first and the second protrusions216aand216bmay include a vertex point, oriented to interfere with the rotational trajectory of the clamp base102about the pivot axis by engagement with the upper wall122of the rail R. Thus, rotation of the clamp base102may be stopped via contact between the horizontally vertex point and the surface of the rail R. While the specific shape of the first and the second protrusions216aand216bmay vary, in an embodiment as shown, each of the first and the second protrusions216aand216bmay be defined as an elongated flange that extends inwardly tapering from one or both ends of the elongation direction of the clamp base102, forming a stopping point. In an embodiment, the taper of the elongated flange tapers such that the clamp base102would engage a beveled sidewalls124aand124bof the rail102in an increasing amount of abutment to slow the engagement and minimize flexion on the pivot joint. In an embodiment, the pivot restraining feature is configured to engage the top surface of the rail R when the clamp base102is rotated to an upright position that is about 90 degrees (between 80-110) relative to the upper wall122of the rail R.

The configuration of the clamp assembly100is optimized to simplify the installation process, requiring only a single tool—a wrench—to attach the solar panel module408to the clamp assembly100. The ability to perform the entire installation with just one tool not only streamlines the assembly process but also enhances the safety of the personnel involved. By minimizing the tools needed, the risk of dropping tools from height or losing grip during installation is reduced, contributing to an efficient installation process.