Abstract:
In various representative aspects, an end clamp that mounts a bottom flange of a solar panel module to a rail support structure without requiring any tools for insertion while mechanically fastening and electrically bonding the solar panel module to the rail support structure. A method of installation is also provided.

Description:
BACKGROUND OF INVENTION 
       [0001]    1. Field of the Invention 
         [0002]    The present invention relates generally to providing an apparatus for securing a solar panel module to a rail support structure. More specifically, the invention relates to the use of an end clamp that mounts a bottom flange of a solar panel module to a rail support structure without requiring any tools for installation, while also mechanically fastening and electrically bonding the solar panel module to the rail support structure. 
         [0003]    2. Description of the Related Art 
         [0004]    Any discussion of the prior art in the specification should in no way be considered as an admission that the prior art is widely known or forms part of common general knowledge in the field. 
         [0005]    The installation of solar panel arrays on residential roofs can be arduous and time-consuming. Depending on the array design, the components required to install the array can make the installation process even more difficult. Many of the assembly components require special tools or are generally difficult to install because they are utilized after the solar panels modules are arranged or positioned on their support elements. 
         [0006]    Solar panel arrays can be installed using different rail support structures. One type of rail support structure utilizes a series of rails that are arranged in rows across a roof and fixed to flashings that are secured to the roof. The solar panels are then arranged in an array and secured to the top of these rails. 
         [0007]    There are various ways to secure the solar panels to the rails. One type of rail support structure includes slots or guides along the top of the rail for receiving mid-clamps or similar mounting hardware used to couple and secure two solar panels to the rails. One reason mid-clamps are advantageous for securing the solar panels to the rails within the interior of the array is that they can secure multiple panels at the same time. This is normally accomplished by inserting an elongated bolt in the rail guide, placing a pair of the solar panels alongside the bolt and joining the panels by tightening a clamp plate to the bolt on top of the panels at the other end of the rail guide. A limitation of these types of mid-clamps is that they are exposed on top of the panels and can be aesthetically unsightly if used along the perimeter of the array. It is desirable to provide a clamp that not only secures the solar panels to the rails outer perimeter of the array, but is also easy to install, electrically grounds the solar panel to the rail guides, and is hidden from plain sight of the array thereby making the outer perimeter of the solar panel array more visibly appealing. The terms “clamp” and “end clamp” are used interchangeably as it applies to the present invention. 
         [0008]    Existing clamps are either unsatisfying in providing a way to secure solar panel modules to rails with guides or slots located on the top of the rails. For example, U.S. Pat. No. 8,590,223 teaches a solar panel assembly attachment apparatus that utilizes a single piece clip that fits linearly within a rail guide and is used to secure a solar panel module to a rail. The device also includes a grounding clip having a barb that attaches to a flange on the solar panel module to ground the module to the rail. But unlike the present invention, this device is secured to the rail guide by utilizing one or more flexible wings that are removably snap-fit into a slot of an elongated and rigid strut. This makes the manufacture and installation of this device more complex than the present invention. 
         [0009]    Another example of a clamp that is used to secure a solar panel module to support rails with guides or slots located on the top of the rail structures is German patent DE 20-2011108873. This patent teaches an end clamp that is inserted within a rail guide as shown in FIG. 2B. One end of the clamp secures a bottom flange of a solar panel to the rail, while the other end is secured outside of the perimeter of the solar panel array by way of a clamping screw. But unlike the present invention, this device does not include unidirectional barbs that act as both grounding features and securing mechanisms that prevent the clamp from coming off the flange of the solar panel once engaged with it. The present invention overcomes the limitations in both of these pieces of prior art and provides a solution that is both easy to, install, use, and manufacture. 
       SUMMARY OF THE INVENTION 
       [0010]    The invention is summarized below only for purposes of introducing embodiments of the invention. The ultimate scope of the invention is to be limited only to the claims that follow the specification. 
         [0011]    It is an object of this invention to provide a clamp for securing a solar panel module to a rail support structure on a residential roof. 
         [0012]    It is a further object of this invention that the clamp fit within, and move bi-directionally along a rail guide of the rail support structure. 
         [0013]    It is a further object of this invention that the clamp is a generally u-shaped body. 
         [0014]    It is a further object of this invention that the u-shaped body includes a top and bottom jaw connected to opposite ends of a rear end. 
         [0015]    It is a further object of this invention that the top and bottom jaws of the clamp can receive a flange of the solar panel module within the clamp. 
         [0016]    It is a further object of this invention that the top jaw of the clamp has at least one raised portion for coupling and electrically bonding to the top surface of the flange of the solar panel module by having the raised portion penetrate an oxidation layer of the flange. 
         [0017]    It is a further object of this invention that the bottom jaw be able to fit within, and move bi-directionally along a guide of the rail support structure. 
         [0018]    It is a further object of this invention that the rear end of the clamp provides sufficient resilience to enable the top and bottom jaws of the clamp to secure the flange to the rail support by gripping the upper and lower surfaces of the flange. 
         [0019]    It is a further object of this invention that the at least one raised portion tapers toward the rear end of the clamp at an acute angle with respect to the top jaw. 
         [0020]    It is a further object of this invention that when the at least one raised portion is engaged with the flange of the solar panel module, the clamp can only move in one direction along the rail guide. 
         [0021]    It is a further object of this invention that in an alternate embodiment, the bottom jaw is elongated and includes an aperture at the end of the bottom jaw. 
         [0022]    It is a further object of the alternate embodiment of this invention to secure the end of the bottom jaw to the rail guide by way of a t-bolt that is inserted through the aperture and into the rail guide, and can be subsequently tightened using a nut. 
         [0023]    It is a further object of this invention to provide a method of assembling a solar panel array utilizing the components described below. 
         [0024]    A person with ordinary skill in the relevant art would know that any shape or size of the elements described below may be adopted as long as the end clamp can be used to secure solar panel modules to the rail support structures and provide a grounding path from the modules to the rail support structures. Any combinations of suitable number, shape, and size of the elements described below may be used. Also, any materials suitable to achieve the object of the current invention may be chosen as well. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0025]    A more complete understanding of the present invention may be derived by referring to the detailed description and claims when considered in connection with the following illustrative figures. In the following figures, like reference numbers refer to similar elements and steps throughout the figures. 
           [0026]      FIG. 1  illustrates a rear perspective view of an exemplary clamp. 
           [0027]      FIG. 2  illustrates a front perspective view of the clamp. 
           [0028]      FIG. 3  illustrates a perspective view of the clamp inserted into a guide of a rail support structure. 
           [0029]      FIG. 4  illustrates a perspective view of the clamp secured between a flange of a solar panel module and the guide of the rail support structure. 
           [0030]      FIG. 7  illustrates an exploded view of the clamp as it moves toward the guide of the rail support structure. 
           [0031]      FIG. 8  is a reverse perspective view of  FIG. 3 . 
           [0032]      FIG. 11  illustrates a side view of the clamp as it moves toward the guide of the rail support structure. 
           [0033]      FIG. 12  illustrates side view of the clamp secured to the solar panel module. 
           [0034]      FIG. 5  illustrates a cross sectional view of the clamp securing the flange of the solar panel module to the guide of the rail support structure. 
           [0035]      FIG. 6  illustrates cross-sectional view of the clamp along points  6 - 6  as shown in  FIG. 5 . 
           [0036]      FIG. 9  illustrates the perspective view of  FIG. 3  showing a solar panel module prior to placing it on top of the rail support structure. 
           [0037]      FIG. 10  illustrates the same view of  FIG. 9  showing the clamp fully engaged with the lower flange of the solar panel module. 
           [0038]      FIG. 13  illustrates a perspective view of a completed assembly of a solar panel module to a pair of rail support structures. 
           [0039]      FIG. 14  illustrates a side view showing the raised portions on the clamp penetrating the surface of the bottom flange of the solar panel module and securing it to the guide. 
           [0040]      FIG. 15  illustrates a solar panel module positioned over two rail structures. 
           [0041]      FIG. 16  illustrates an exploded view of an alternate embodiment of the end clamp with an elongated lower portion. 
           [0042]      FIG. 16A  illustrates a side view of the clamp. 
           [0043]      FIG. 16B  illustrates a top view of the clamp. 
           [0044]      FIG. 16C  illustrates a bottom view of the clamp. 
           [0045]      FIG. 17  illustrates a perspective view of the elongated clamp as it moves toward the guide of the rail support structure. 
           [0046]      FIG. 18  illustrates a perspective view of the elongated clamp installed on the guide of the rail support structure. 
           [0047]      FIG. 19  illustrates the perspective view of  FIG. 18  showing a solar panel module prior to placing it on top of the elongated end clamp. 
           [0048]      FIG. 20  illustrates the same view of  FIG. 19  showing the clamp fully engaged with the lower flange of the solar panel module. 
           [0049]      FIG. 21 . Illustrates a side view of  FIG. 20 . 
           [0050]      FIG. 22  illustrates the same view as  FIG. 21  showing the nut on the t-bolt being tightened. 
           [0051]      FIG. 23  illustrates a cross-sectional view of  FIG. 21 . 
           [0052]      FIG. 24  illustrates a perspective view of a completed assembly. 
           [0053]      FIG. 25  illustrates a side view of the clamp with the solar panel module inserted into the clamp. 
           [0054]      FIG. 26  illustrates a cross-sectional view of ( 26 - 26 ) from  FIG. 25 . 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0055]    In the following description, and for the purposes of explanation, numerous specific details are provided to thoroughly understand the various aspects of the invention. It will be understood, however, by those skilled in the relevant arts, that the present invention may be practiced without these specific details. In other instances, known structures and devices are shown or discussed more generally in order to avoid obscuring the invention. In many cases, a description of the operation is sufficient to enable one to implement the various forms of the invention, particularly when the operation is to be implemented in software. It should be noted that there are many different and alternative configurations, devices and technologies to which the disclosed embodiments may be applied. The full scope of the invention is not limited to the example(s) that are described below. 
         [0056]      FIGS. 1 and 2  show two perspective views of an end clamp  100  for use in fastening a solar panel module to a rail support structure  200  (as shown in  FIGS. 3 and 4 ). The exemplary embodiment of the end clamp  100  is generally a c-shaped or u-shaped structure that includes a top jaw  110 , a rear end  120 , and a bottom jaw  130 . The top and bottom jaws  110  and  130  are typically in the form of flanges, but can be of any suitable shape that forms a mouth-like opening with respect to the rear end  120 . The end clamp  100  is typically made from an electrically conducting material. In this embodiment, a pair of bottom side flanges  135  are also included and are positioned on opposite sides of the bottom jaw  130 . The bottom side flanges  135  provide added stability and gripping area of the flange  310  as discussed below. The rear end  120  is slightly flexible so that it allows a limited amount of angular movement of the top and bottom jaws  110  and  130  when they are pulled outward or recoil inward. A pair of apertures  140  are positioned between the two bottom side flanges  135 . The apertures  140  extend from the terminal ends of the bottom side flanges  135  to rear portions  115  of the top jaw  110 . 
         [0057]      FIG. 2  shows the front of the end clamp  100 . The top jaw  110  includes raised portions  150  that protrude downward. A plurality of raised portions  150  is desired, but one raised portion  150  may be sufficient. The raised portion  150  preferably tapers to a sharp point  155 . The raised portions  150  are directed toward the rear end  120  of the end clamp  100  so that the point  155  is at an acute angle with respect to the top jaw  110 . 
         [0058]    The purpose of the end clamp  100  is to secure a solar panel module to a rail support structure.  FIGS. 3 and 4  show a typical configuration with a rail support structure  200  and a solar panel module  300  that includes a flange  310  on its lower end. The rail support  200  is normally secured to a flashing structure that has been previously installed on a roof (not shown) and includes a guide  210  on or near the top of the support  200  for receiving the end clamp  100 . 
         [0059]    The process of securing the solar panel module  300  to the rail support  200  is accomplished by inserting the bottom jaw  130  of the end clamp  100  into an open end  225  of the guide  210  and enabling the apertures  140  to follow the contour of the upper and side walls  220  of the guide  210  as shown in  FIGS. 5 and 6 . The bottom side flanges  135  flank the outer portions of the side walls  220  as the end clamp  100  is inserted into the guide  210 . An exemplary bottom jaw  130  will frictionally engage the inner walls  230  of the guide  210  while allowing the end clamp  100  to move bi-directionally along the guide  210 . All of this can normally be accomplished without the use of any tools. 
         [0060]    As shown in  FIGS. 7, 8, and 11 , the solar panel module  300  is placed on top of the rail support  200  so that the lower flange  310  is substantially perpendicular to the guide  210 . The end clamp  100  is then manually pushed along the guide  210  toward the lower flange  310  of the solar panel module  300 . The space between the top jaw  110  and bottom jaw  130  is sufficient to allow the bidirectional movement to occur along the guide  210 . As shown in  FIGS. 9, 10, and 14 , the end clamp  100  forms a tight grip of the lower flange  310  as the top jaw  110  of the end clamp  100  engages the top surface of the lower flange  310 , and the bottom jaw  130  engages the bottom surface of the lower jaw  130 . Preferably, the rear end  120  provides sufficient resiliency to enable the top jaw  110  and lower jaw  13  to provide an adequate gripping force to compress the lower flange  310  to the guide  210 . Once engaged, the points  155  of the raised portions  150  are then deflected slightly upward toward the top jaw  110  and form a tight grip on the top surface of the lower flange  310 . The slight deflection allows the end clamp  100  to continue to move along the guide  210  toward the solar panel module  300  until the lower flange  310  reaches the rear end  120  of the end clamp  100 . As shown in  FIGS. 9 and 10  once engaged, the sharp points  155  penetrate the outer surface layer of the lower flange  310  and create a grounding path from the solar panel module  300  to the rail support  200  through the end clamp  100 . 
         [0061]    Once penetration of the surface layer occurs, the combination of the rearward-pointing angle of the raised portions  150  with the tightness of the gripping force formed between the top jaw  110  and the bottom jaw  130 , allow the points  155  to resist any attempt to pull the end clamp  100  away from the solar panel module  300  essentially locking the solar panel module  300  in place. The end clamp  100  can be unlocked and moved backward along the guide  210  by pulling the top jaw  110  and the bottom jaw  130  apart so that the raised portions  150  disengage from the lower flange  310 . 
         [0062]      FIG. 13  shows a perspective view of the clamp  100  fully engaged and securing the solar panel module  300  to the rail support  200  and providing an electrical conducting path between the them.  FIG. 12  shows a view from the opposite side of the solar panel module  300  and  FIG. 15  shows the solar panel module  300  as it rests on two distinct rail supports  200  demonstrating that the end clamp  100  is hidden from plain view. This process is repeated until all end clamps  100  are installed. After the first row is installed, each subsequent row is installed by repeating the process described above. 
         [0063]      FIG. 16  shows an exploded view of an alternate end clamp  400 . The end clamp  400  includes some of the same features as the end clamp  100  in terms of how it engages and secures the lower flange  310  on the solar panel module  300 . But in this embodiment, the end clamp  400  provides an additional means to secure the end clamp  100  to the rail support  200 . As in the previous end clamp  100 , the end clamp  400  is also a generally c-shaped or u-shaped clamp that includes a top jaw  410 , a rear end  420 , and a bottom jaw  430 . The top and bottom jaws  410  and  430  are typically in the form of flanges, but can be of any suitable shape that forms a mouth-like opening with respect to the rear end  420 . The end clamp  400  is typically made from an electrically conducting material. 
         [0064]    In this embodiment, the bottom jaw  430  is extended outward beyond the edge of the top jaw  410  and includes an aperture  470  for receiving a t-bolt  490  as shown in  FIG. 15  to secure the end clamp  400  to the rail support  200 . The t-bolt  490  is typically an elongated threaded bolt with a rectangular-shaped head on one end and includes raised portions  495  on the head that are used to grip the inside of the guide  210  of the rail support  200  as will be discussed below. The aperture  470  is typically positioned in the middle of the bottom jaw  430  and allows for the t-bolt  490  to be inserted and secured in various locations along the center of the bottom jaw  430 . The t-bolt  490  is tightened using a nut  480 . 
         [0065]    An optional back support  460  is also included. An exemplary back support  460  is L-shaped and includes a vertical face  462  with ridges  465  and a horizontal face  467  with an aperture  468  for receiving the t-bolt  490 . 
         [0066]      FIG. 16A  shows a side view of the end clamp  430 , which also includes the raised portions  450  of top jaw  410  that protrudes downward. The structure of the raised portions  450  is the same as those shown in  FIG. 2  for the first embodiment of the clamp  100 . A plurality of raised portions  450  is desired, but one raised portion  450  is sufficient. The raised portions  450  preferably taper to a sharp point  455 . As shown, the raised portion  450  is directed toward the rear end  420  of the end clamp  400  so that the point  455  is at an acute angle with respect to the top jaw  410 . 
         [0067]      FIG. 16B  shows a top view of the end clamp  400  showing the features as described above while  FIG. 16C  shows a bottom view of the end clamp  400 . The bottom view shows the entirety of the bottom jaw  430  with the aperture  470  and grooves  425 . The head  485  of the t-bolt  490  is shown having been inserted through the aperture  470 . 
         [0068]    As it was with the end clamp  100 , the purpose of the end clamp  400  is to secure a solar panel module to a rail support structure.  FIG. 19  shows a typical configuration with a rail support structure  200  and a solar panel module  300  that includes a flange  310  on its lower end. Just as with the end clamp  100 , the end clamp  400  is positioned in the guide  210  of the rail support  200  as shown in  FIGS. 17 and 18  along the grooves  425  where it can move bi-directionally along the guide  210 . 
         [0069]    The process of securing the solar panel module  300  to the rail support  200  in this embodiment is accomplished by placing the solar panel module  300  on top of the bottom jaw  430  so that the lower flange  310  is generally perpendicular to the guide  210  as shown in  FIG. 20 . 
         [0070]      FIG. 21  shows a side view of the configuration. The lower flange  310  of the solar panel module  300  is then inserted the through the mouth of the top jaw  410  and bottom jaw  430  of the end clamp  400  so that the end clamp  400  forms a tight grip of the lower flange  310  as the top jaw  410  of the end clamp  400  engages the top surface of the lower flange  310 , and the bottom jaw  430  engages the bottom surface of the lower jaw  430 . The vertical face  465  of the optional back support  460  engages the rear surface  350  of the solar panel module  300  providing further support of the module  300 . 
         [0071]      FIG. 23  shows a cross-sectional view ( 23 - 23 ) from  FIG. 21 . The points  455  of the raised portions  450  are then deflected slightly upward and form a tight grip on the top surface of the lower flange  310 . The deflection allows the end clamp  400  to continue to move along toward the solar panel module  300  until the lower flange  310  engages the rear end  420  of the end clamp  400 . As they did with the clamp  100  discussed previously, once engaged, the sharp points  455  penetrate the outer surface layer of the lower flange  310 . 
         [0072]    As shown in  FIGS. 25 and 26 , once penetration of the surface layer occurs, the combination of the rearward-pointing angle of the raised portions  450  with the force of the grip formed between the top jaw  410  and the bottom jaw  430 , allow the points  455  to resist any attempt to pull the end clamp  400  away from the solar panel module  300  essentially locking the solar panel module  300  in place. 
         [0073]    As shown in  FIG. 23 , the t-bolt  490  is inserted through the aperture  468  of the optional back support  460  and through the aperture  470  of the bottom jaw  430  into the guide  210 . The nut  480  is then placed on the threaded portion of the t-bolt  490  and turned clockwise so that the t-bolt  490  engages the inner walls of the guide  210 . The raised portions  492  on the outer edges of the t-bolt  490  cause the t-bolt  490  to stop rotating so that the nut  480  can continue to turn and tighten the bottom jaw  430  to the guide  210  of the rail support  200  as shown in  FIG. 23  thereby creating an electrical conducting path from the solar panel module  300  to the rail support  200  through the end clamp  400 . 
         [0074]    The end clamp  400  can be released and removed from the end clamp  400  by pulling the top jaw  410  and the bottom jaw  430  apart so that the raised portions  450  disengage from the lower flange  310 . This process is repeated until all end clamps  400  are installed.  FIG. 24  shows the solar panel module  300  as it rests on two distinct rail supports  200  After the first row is installed, each subsequent row is installed by repeating the process described above.