Abstract:
A photovoltaic (PV) mounting hardware support system having a base portion. The system includes a hinged clamp having a first clamp portion hingedly connected to a second clamp portion and operable to lock and unlock the first clamp portion and second clamp portion to the base portion. A beam member is provided and configured as a mount for a PV module coupling device. The beam member is clamped between the first clamp portion and second clamp portion.

Description:
CROSS REFERENCE RELATED APPLICATIONS 
       [0001]    This application is related to co-assigned and co-invented patent application Ser. No. ______ (Attorney Docket No. P133-2NUS), entitled “Wedge Spring Clip Mounting System for Photovoltaic Modules, filed on Jul. 15, 2015, which is incoporated by reference herein. 
     
    
     BACKGROUND OF THE INVENTION 
       [0002]    There are many systems availiable for mounting photovoltaic (PV) modules to building structures, such as a roof. These systems serve as a rigid interconnetion element between a roof and a PV module to hold the modules in place and resist the forces of gravity and wind. 
         [0003]    Traditionally, mounting systems consisted of rows of rail structures attached to the roof in columns or rows. Module clamps were used to attach the PV modules to these rail structures. Although effective, these traditional systems required complex and time-consuming installations and utilized relatively large amount of materials. Eventually, pioneers in the solar industry, such as Jack West of San Rafael-based Zep Solar, realized that module frames themselves are sufficiently rigid to function as the rails of a PV mounting system. By utilizing the inherent rigidity of modules frames as part of the PV mounting system, system part counts and costs of PV mounting systems were significantly reduced while installation time and overall aesthetics were improved. This realization caused the majority of the residential solar industry to move away from rail-based solutions. However, in order to continue the momentum of solar against other fossil fuel-based energy sources, it is imperative that both hard and soft PV costs continue to be reduced. 
         [0004]    Most rail-free or so-called direct mount systems, rely on pillar-like PV module supports which connect to each module frame at various points around the array—typically at least four points on each module. These module supports are in turn attached to the roof, either into a roof rafter or directly to the roof deck, via a flashing. The flashing is just a flat sheet of aluminum with a preformed feature designed to mate with the module support and typically including at least one lag-bolt through-hole for securing both the flashing and the module support to the roof. 
         [0005]    Although effective at reducing water leaks and covering missed drill holes, flashings can increase the time of installation because when they are used, the installer must complete all site preparation first before placing any of the PV modules, installing a flashing at each intended roof penetration. This bottleneck prevents an installer from installing the array row-by-row or panel-by-panel and, as a result, may slow-down the rate at which PV can be installed, may require larger installation crews, or both. Also, because each flashing gets tucked underneath the next up-roof course of shingles, it is often necessary to remove existing roofing nails to accommodate the flashings. Each time an existing roofing nail is removed, a new potential leak point is created. Finally, each flashing adds a material cost to each solar installation that becomes significant when multiplied against every roof penetration of every installed array. 
         [0006]    Accordingly, there is a need for a rail-free PV mounting system that enjoys the benefits of existing rail-free solutions, while reducing costs, and increasing installation times relative to such systems. 
       BRIEF SUMMARY OF THE INVENTION 
       [0007]    Many embodiments are related to photovoltaic (PV) mounting system having a base portion that can be substantially planar and have a first roof-facing side and an opposite PV array facing side. The base portion can include a lip that circumscribes the perimeter of the base portion and curves inward on the array facing side. A hinged clamp is provided that includes a pair of flanges, In a first open position of the hinged clamp, the flanges are insertable into the array-facing opposite side of the base portion and in a second closed position of the hinged clamp the flanges are expanded to engage the lip of the base portion to selectively couple the hinged clamp to the base portion and define two circular openings that are substantially orthogonal to the plane of the base portion. At least one locking tab can be formed in the hinged clamp operable to selectively lock and unlock the hinged clamp. The hinged clamp captures a tubular beam member when it is locked in the second closed position, the beam member passing through the two circular openings defined by the clamp. At one end, the tubular beam member supports a PV coupling device that in turn couples to the frames of at least two photovoltaic modules. 
         [0008]    In many embodiments, the base portion can be a circular puck having a through-hole for mounting the base portion to a structure by a lag-bolt. 
         [0009]    In many embodiments, in the second closed position of the clamp, the pair of flanges forms a boxed structure extending upwardly from the base portion. 
         [0010]    In many embodiments, the clamping flanges can have a splined clamping surface configured for gripping the tubular beam member. 
         [0011]    In many embodiments, the tubular beam member can have a splined beam surface for gripping the splined surface of the clamping flanges. 
         [0012]    In many embodiments, moving the hinged clamp to the second position spreads the flanges outwardly from each other and into the lip of the base portion. 
         [0013]    In many embodiments, each of the flanges can include a pair of semi-circular edges that form the two circular openings. 
         [0014]    In many embodiments, the semi-circular edges apply a compressive force against the tubular beam member. 
         [0015]    In many embodiments, the PV module coupling device is a pivot locking coupling device. 
         [0016]    In many embodiments, the PV module coupling device includes an upper and lower clamp. 
         [0017]    Many embodiments are also related to a photovoltaic (PV) mounting hardware support system having a base portion. A hinged clamp that includes a pair of flanges connected by hinges can be provided. In a first open position of the hinges, the hinged clamp may be freely inserted into the base portion and in a second closed position of the hinges, the hinged clamp is locked to the base portion. A beam member can be provided and configured as a mount for a PV module coupling device. In the second position of the hinged clamp the beam member is forcibly held between openings formed by the pair of flanges. 
         [0018]    In many embodiments, the base portion can be a circular puck adapted to mount to a structure via a lag bolt. 
         [0019]    In many embodiments, the base portion includes a lip that the pair of flanges forcibly locks within. 
         [0020]    In many embodiments, the pair of flanges forms a boxed structure for holding the beam member. 
         [0021]    In many embodiments, the pair of flanges can include locking tabs configured to maintain the pair of flanges in position to forcibly hold the beam member. 
         [0022]    In many embodiments, the pair of flanges include splined surfaces for engaging the beam member. 
         [0023]    Many embodiments are also related to a photovoltaic (PV) mounting hardware support system that includes a base portion. A hinged clamp is provided that includes a first clamp portion hingedly connected to a second clamp portion. The hinged clamp may be operable to lock and unlock the first clamp portion and second clamp portion to the base portion. A beam member can be provided that serves as a mount for a PV module coupling device. The beam member can be clamped between the first clamp portion and second clamp portion. 
         [0024]    In many embodiments, the base portion can include a lip that the first clamp portion and second clamp portion lock to. 
         [0025]    In many embodiments, the hinged clamp can include a first hinge and a second hinge that hingedly connect the first clamp portion and second clamp portion. 
         [0026]    In many embodiments, the hinged clamp can close to form a boxed structure about the beam member. 
         [0027]    In many embodiments, the hinged clamp can include wedges that forcibly lock into the base portion. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0028]      FIGS. 1A and 1B  show perspective views of an exemplary PV mounting system, according to an embodiment of the invention. 
           [0029]      FIG. 1C  shows an exploded view of an aspect of the system of  FIG. 1A , according to an embodiment of the invention. 
           [0030]      FIGS. 2A and 2B  show operational views of the system of  FIG. 1A , according to an embodiment of the invention. 
           [0031]      FIG. 3  show the system of  FIG. 1A  in use, according to an embodiment of the invention. 
           [0032]      FIG. 4  shows a perspective view of another exemplary PV mounting system, according to an embodiment of the invention. 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0033]    Embodiments of the invention are generally directed towards a system for mounting a PV module to a support structure such as a roof surface. The system can include a base portion assembly and a clamp assembly for supporting a PV module. The clamp assembly may include a hinged clamp that when actuated from a first position to a second position with the base portion assembly, provides a boltless system for rigidly fixing the clamp assembly to the base portion assembly in a sufficient manner to permanently support the weight of one or more PV modules. Advantageously, such as system requires little to no tools for installation, and hence installation time is greatly reduced over prior systems that require additional tools and bolting. The following description details some examples of such a system. 
         [0034]      FIGS. 1A and 1B  show perspective views of an exemplary system  100  for mounting a PV module to a structure, such as a roof. The system  100  includes a base portion  102 , which here is formed as a puck having an inner lip  104  that can curve inwardly. The base portion  102  has a lower roof-facing surface that is configured to directly or indirectly mount to a support structure, and can include one or more passages for accommodating a fastener such as a lag bolt  103 . In various embodiments, for example, as illustrated in  FIG. 1C , lag bolt  103  may be installed through an opening formed in base portion  103  so as to penetrate the roof surface at a point over a roof rafter. This may be accomplished by drilling a pilot hole at the desired point in the roof over the roof rafter prior to lagging in lag bolt  103  through base  102 . It should be appreciated that although there is only a single lag bolt hole in base portion  102 , in various embodiments, it may be desirable to have two or more through-holes to permit more than one fastening point to the roof surface. Moreover, base portion  102  is not limited to the puck-like design illustrated in the figures. For example, inner lip  104  may be integrated into a flashing or specialized shingle to provide the functionality of base portion  102  in a different form. 
         [0035]    With continuing reference to  FIGS. 1A-C , clamp  106  extends upwardly from a PV module-facing side of base portion  102 . Clamp  106  includes first clamp portion  108  hingedly connected to second clamp portion  110 , which as shown at  FIG. 1A , forms a boxed structure that holds elongated support beam  112 . Elongated support beam  112  is configured here as a tube having a splined surface for gripping the clamp  106 . It should be appreciated, however, that in various embodiments, beam  112  may include cross-hatching, may be knurled, or may simply be textured to increase friction with clamp  106 . Elongated support beam  112  in turn supports PV module coupling device  114  that is configured to couple to the frames of at least two photovoltaic modules. 
         [0036]    The PV module coupling device  114  shown in the aforementioned figures is a “rock-it” style connector manufactured by SolarCity Corp., which is arranged to connect to the frames of two adjacent PV modules. Such a coupling device is described and illustrated, for example, in commonly assigned U.S. patent application Ser. No. 14/615,320, Publication No. 2015/0155823-A1, the disclosure of which is herein incorporated by reference in its entirety. However, the system  100  is not limited to use of such a coupling device. A multitude of different styles of coupling devices are compatible with the system, for example, such as the coupling device  130  illustrated at  FIG. 4 , which depicts a clamping-style coupling device  130  with an upper and lower clamp arranged to clamp the top and bottom portions of a PV module. A clamping-style coupling device typically utilizes a rigid base portion and a movable top clamping portion that under pressure from a top-mounted bolt, compresses the movable top-clamping portion towards the base portion, thereby compressing the respective frames of two photovoltaic modules. The various embodiments of the invention may be used with a variety of different types of PV module coupling devices. 
         [0037]    Continuing with the exemplary embodiment illustrated in  FIGS. 1A-C , elongated support beam  112  is configured as a tube, which allows for rotational as well as longitudinal adjustment of PV coupling device  114  with respect to base portion  102  during installation and module placement. For example, in various embodiments, spring  106  will be free to rotate 360 degrees within base portion  102 . Also, longitudinal adjustment may be made by moving coupling device  114  toward or away from spring  106  before fully compressing spring  106  into the second closed position. As discussed above, in at least one embodiment, the exterior surface of the elongated support beam  112  is splined to prevent rotation with respect to the clamp  106 . In addition, interior facing edges  114  of clamp  106  may also be geared or toothed in a reciprocal manner to fit snuggly together with the external spline of support beam  112 . Alternatively, interior facing edges  114  of the clamp  106  may simply be knurled or textured, such as with cross-hatching, to increase friction with support beam  112 . While shown as a tube, additional shapes are possible for the elongated support beam  112 , such as a rectangular or hexagonal shape. 
         [0038]    As shown at  FIG. 1B , first clamp portion  108  is connected to second clamp portion  110  by way of hinges  116 . Interior facing edges  114  of each clamp portion are semi-circular, such that when first clamp portion  108  is brought together with second clamp portion  110 , two co-axial circular openings are formed. Each clamp portion also includes at least one, and preferably a pair of tabs such as tabs  118  for selectively maintaining the clamp portions together. Each clamp portion also includes wedge portion  120  having a duck-bill shape approximating a portion of the circle circumscribed by lip  104  of base portion  102  and adapted to forcibly wedge within the lip  104  of the base portion  102 . 
         [0039]    A tool-free and boltless operation for installing the system  100  is shown at  FIGS. 2A and 2B , after the base portion  102  is pre-installed to a structure, such as a roof, for example, using the methodology discussed in the context of  FIG. 1C . As shown, clamp  106  is arranged within base portion  102 , with wedge portions  120  tucked into lip  104 . When clamp  106  is fully opened, it can be freely inserted into base  102  at an infinite number of different rotational angles by simply turning clamp  106  within base portion  102 . The elongated support beam  112  is then brought down between first clamp portion  108  and second clamp portion  110 , and placed in a desired location with respect to rotational and longitudinal placement of the PV module coupling device  114 . This is particular useful to accommodate situations where the interconnection point between two adjacent PV modules is not co-located with a roof rafter. 
         [0040]    After support beam  112  has been placed at the desired location, and in some cases after coupling device  114  was been attached to the frame of one of the photovoltaic modules (e.g., the down-roof module using tongue side of coupling device  114 ), first clamp portion  108  and second clamp portion  110  are then closed shut about elongated support beam  112  until tabs  118  are locked to each other, thus forming a boxed structure, as shown at  FIG. 2B . As noted above, the interior facing edges  114  form two circular openings, which can be sized to have zero or negative clearance with respect to the outer diameter of the elongated support beam  112 . Hence, the first clamp portion  108  and second clamp portion  110  are brought together such that a compressive force is placed on the elongated support beam  112  by the interior facing edges  114 , to prevent any slippage. In various embodiments, this is accomplished by simply applying manual compression to clamp portions  108  and  110  until tabs  118  become locked. 
         [0041]    As the first clamp portion  108  and second clamp portion  110  are closed shut, wedge portions  120  spread outwardly and become completely wedged into lip  104 , as shown at  FIG. 2B , thus locking clamp  106  securely into the base portion  102 , and preventing rotational, lateral, and vertical displacement of the clamp  106  with respect to the base portion  102 . This in turn insures that module coupling device  114 , and by extension photovoltaic modules in the array that are supported by module coupling device  114 , remain in place at the same location. Accordingly, the system  100  provides a substantially tool-free method of installing and adjusting a PV module support device. 
         [0042]    If placement of the system  100  is incorrect, or if for whatever reason, an installer needs to remove the module attached to coupling device  114 , the installer need only unclasp tabs  118  to open the clamp  106 , reposition the elongated support beam  112  as desired, and then reclose the clamp  106 . This may be accomplished by merely compressing spring portions  108  and  110  towards each other until tabs  118  release or by inserting a screw driver or other tool directly into tables  118  until they release. 
         [0043]      FIG. 3  shows a plurality of systems  100  mounted to a roof and supporting an array of PV modules. While the system  100  is shown mounted to a sloped roof, the system  100  can be used on a variety of structures. Moreover, although the roof shown in  FIG. 3  is a composition shingle roof, the mounting system  100  according to the various embodiments may be used with a flat tile, curved tile, shake, or other type of residential or commercial roof. 
         [0044]    Other variations are within the spirit of the present invention. Thus, while the invention is susceptible to various modifications and alternative constructions, certain illustrated embodiments thereof are shown in the drawings and have been described above in detail. It should be understood, however, that there is no intention to limit the invention to the specific form or forms disclosed, but on the contrary, the intention is to cover all modifications, alternative constructions, and equivalents falling within the spirit and scope of the invention, as defined in the appended claims. 
         [0045]    The use of the terms “a” and “an” and “the” and similar referents in the context of describing the invention (especially in the context of the following claims) are to be construed to cover both the singular and the plural, unless otherwise indicated herein or clearly contradicted by context. The terms “comprising,” “having,” “including,” and “containing” are to be construed as open-ended terms (i.e., meaning “including, but not limited to,”) unless otherwise noted. The term “connected” is to be construed as partly or wholly contained within, attached to, or joined together, even if there is something intervening. Recitation of ranges of values herein are merely intended to serve as a shorthand method of referring individually to each separate value falling within the range, unless otherwise indicated herein, and each separate value is incorporated into the specification as if it were individually recited herein. All methods described herein can be performed in any suitable order unless otherwise indicated herein or otherwise clearly contradicted by context. The use of any and all examples, or exemplary language (e.g., “such as”) provided herein, is intended merely to better illuminate embodiments of the invention and does not pose a limitation on the scope of the invention unless otherwise claimed. No language in the specification should be construed as indicating any non-claimed element as essential to the practice of the invention. 
         [0046]    Preferred embodiments of this invention are described herein, including the best mode known to the inventors for carrying out the invention. Variations of those preferred embodiments may become apparent to those of ordinary skill in the art upon reading the foregoing description. The inventors expect skilled artisans to employ such variations as appropriate, and the inventors intend for the invention to be practiced otherwise than as specifically described herein. Accordingly, this invention includes all modifications and equivalents of the subject matter recited in the claims appended hereto as permitted by applicable law. Moreover, any combination of the above-described elements in all possible variations thereof is encompassed by the invention unless otherwise indicated herein or otherwise clearly contradicted by context.