Patent Publication Number: US-2023151834-A1

Title: Clamp assembly using pins

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application is a continuation-in-part of, and claims the benefit of, co-pending U.S. patent application Ser. No. 17/164,839, filed on Feb. 1, 2021, which is a continuation of U.S. patent application Ser. No. 15/907,229 filed Feb. 27, 2018 now U.S. Pat. No. 10,907,670, which is a continuation of U.S. patent application Ser. No. 14/443,567 filed May 18, 2015 now U.S. Pat. No. 9,957,988, which is a national stage entry of PCT/US2014/046242 filed Jul. 10, 2014, which claims priority from U.S. Provisional Application No. 61/844,763 filed on Jul. 10, 2013, and the entire disclosure is hereby incorporated by reference herein. 
    
    
     TECHNICAL FIELD 
     The present invention is in the field of clamps and/or mounting assemblies that may be used for securing a device generally to an edge of a structure such as a raised portion of a standing seam of a metal roof, with the clamp configuration providing an improved hold that resists loosening from environmental conditions, including high winds, seismic vibration, and snow loads. 
     BACKGROUND 
     Conventional clamps and/or mounting assemblies are useful in consumer and/or industrial applications, for example, a metal roof uses clamp(s) to attach panels, solar panels, snow rails, wind clamps, signs, HVAC equipment, conduit and the like to an edge such as a standing seam formed by overlapping tiles or panels in a known way. The panels or tiles can be formed from metals and/or metal alloys such as for example, copper, aluminum, zinc coated steel, stainless steel, or other composite blend of such metals. Elongated panels are arranged longitudinally across a roof—from ridge line to overhang—overlapped and joined to form an edge that is termed a standing seam. 
     Moreover, conventional systems are constantly affected by thermal movement and vibration actions Thermal movement of the attachment system occurs as the metal of a roof is heated and cooled by the sun, and under snow loads. For example, threaded fasteners in clamps can loosen by the expanding and contracting to the point that the clamp can slide along the standing seam. Another condition that loosens clamps is vibration, for example, fasteners can torque, back-out, or otherwise loosen a clamp secured to the standing roof from high winds and seismic vibration, e.g. traffic, normal earth vibration, earthquakes and the like. In such applications a variety of systems and clamps are designed to withstand thermal and vibration activity to maintain a secure hold of devices and things attached to the edge, e.g. solar panels, satellite dishes, antennae, and other things e.g. footholds, guides, snow breaks, structures or general supports to the metal roof standing seam. As a result, there is a need in the art for improvements in holding clamps on a standing seam that overcomes the problem of thermal movement and that overcomes the problems of loosening from vibration and other factors. 
     Still other problems involve matching the standing seam to a particular clamp, which may be limited by the clamp&#39;s geometry and/or structure. Because securely locking to a standing seam depends upon the profile of the seam, i.e., the cross-sectional profile defining how the interlocking-portions couple to one another, conventional clamp designs commonly need to be tailored for, and selected according to, a specific profile. As a result, there is a need in the art for an improved, non-penetrating, and versatile clamp that accepts an edge with unique geometry structure so as not to limit the use and/or applications of the clamp. 
     SUMMARY 
     The present invention provides a versatile clamp assembly, capable of coupling to and securing a load to an edge of a structure such as the standing seam of a metal roof panel. The clamp is adapted to couple to a wide variety of seam profile geometries thereby reducing the amount of customization necessary in the fabrication, production, and/or assembly thereof. The clamp assembly is configured to substantially eliminate damage to the clamped edge of the structure, to provide an improved hold on the edge that does not diminish under the influence of human and environmental forces over time. In one aspect, the clamp assembly according to the present invention achieves this hold via pins configured to be inserted in smooth, non-threaded openings that provide translatable, rather than rotatable, coupling to the seam, thereby eliminating damage to the surface that occurs in conventional design. Therefore, the clamp assembly eliminates or substantially eliminates the aforementioned problems associated with conventional designs, including leakage, limiting the life of the roof from degradation, oxidation, taking away from the appearance, and voiding a manufacturer&#39;s warranty. 
     A further object of the present invention is to provide a versatile clamp assembly that may be used for securing a device generally to an edge of a structure such as a raised portion of a standing seam of a metal roof. The clamp assembly comprises a mounting body with an open loop having a slot for receiving the raised portion formed the mounting body attaching the clamp assembly thereto. The clamp body has a slot and/or side portions adapted to accept wide-profile seams, including but not limited to bulb-style and T-panel seam profiles. 
     A further object of the present invention is to provide a clamp assembly comprising pins having an improved length-of-travel, which may be adapted to accept wide-profile seams, including but not limited to bulb-style and T-panel seam profiles. 
     A further object of the present invention is to provide a clamp assembly comprising pins configured to travel, i.e., translate, and couple to, the standing seam at a substantially non-orthogonal angle, i.e., non-normal angle, with respect to the surface of contact of the seam. This arrangement provides certain advantages, including providing an improved clearance of the slot, and/or an increase in distance of the fastener head with respect to the roof surface, which may aid in coupling tools thereto, e.g., an electric screw driver. 
     In a further object of the present invention, the design provides improved manufacturability and reduced cost. 
     Other desirable features and characteristics will become apparent from the subsequent detailed description, the drawings, the abstract, and the claims, when considered in view of this summary. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       Non-limiting and non-exhaustive embodiments of the present invention are described with reference to the following drawings. In the drawings, like reference numerals refer to like parts throughout the various figures unless otherwise specified. 
       For a better understanding of the present invention, reference will be made to the following Detailed Description, which is to be read in association with the accompanying drawings, which are incorporated in and constitute a part of this specification, show certain aspects of the subject matter disclosed herein and, together with the description, help explain some of the principles associated with the disclosed implementations, wherein: 
         FIG.  1    illustrates a front, top, left-side perspective view of a clamp assembly for coupling a device to a standing seam of a metal roof panel, in accordance with an embodiment of the present invention; 
         FIG.  2    illustrates a front, bottom, left-side, partially-exploded, perspective view of a clamp assembly for coupling a device to a standing seam of a metal roof panel, in accordance with an embodiment of the present invention; 
         FIG.  3    illustrates a front, top, left-side perspective view of a clamp body for coupling a device to a standing seam of a metal roof panel, in accordance with an embodiment of the present invention; 
         FIG.  4    illustrates a rear, top, left-side perspective view of a clamp body for coupling a device to a standing seam of a metal roof panel, in accordance with an embodiment of the present invention; 
         FIG.  5 A  illustrates a left-side view of a clamp body including a body base portion, in accordance with an embodiment of the present invention; 
         FIG.  5 B  illustrates a left-side view of a clamp body including a body base portion, in accordance with another embodiment of the present invention; 
         FIG.  6 A  illustrates a clamp assembly coupled to a standing seam having a bulb-style profile, wherein the standing seam is shown without any substantial deformation for clarity, in accordance with an embodiment of the present invention; 
         FIG.  6 B  illustrates a clamp assembly coupled to a standing seam having a T-panel profile, wherein the standing seam is shown without any substantial deformation for clarity, in accordance with an embodiment of the present invention; 
         FIG.  7 A  illustrates a clamp assembly coupled to a standing seam having a bulb-style profile, wherein the standing seam is shown without any substantial deformation for clarity, in accordance with an alternative embodiment of the present invention; and 
         FIG.  7 B  illustrates a clamp assembly coupled to a standing seam having a T-panel profile, wherein the standing seam is shown without any substantial deformation for clarity, in accordance with an alternative embodiment of the present invention. 
     
    
    
     DETAILED DESCRIPTION 
     Non-limiting embodiments of the present invention will be described below with reference to the accompanying drawings, wherein like reference numerals represent like elements throughout. While the invention has been described in detail with respect to the preferred embodiments thereof, it will be appreciated that upon reading and understanding of the foregoing, certain variations to the preferred embodiments will become apparent, which variations are nonetheless within the spirit and scope of the invention. 
     The terms “a” or “an”, as used herein, are defined as one or as more than one. The term “plurality”, as used herein, is defined as two or as more than two. The term “another”, as used herein, is defined as at least a second or more. The terms “including” and/or “having”, as used herein, are defined as comprising (i.e., open language). The term “coupled”, “operably coupled” as used herein, is defined as connected, secured, fixedly attached, or rigidly attached, although not necessarily directly, and not necessarily mechanically and that can be de-coupled. 
     Reference throughout this document to “some embodiments”, “one embodiment”, “certain embodiments”, and “an embodiment” or similar terms means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the present invention. Thus, the appearances of such phrases or in various places throughout this specification are not necessarily all referring to the same embodiment. Furthermore, the particular features, structures, or characteristics may be combined in any suitable manner in one or more embodiments without limitation. 
     The term “or” as used herein is to be interpreted as an inclusive or meaning any one or any combination. Therefore, “A, B or C” means any of the following: “A; B; C; A and B; A and C; B and C; A, B and C”. An exception to this definition will occur only when a combination of elements, functions, steps or acts are in some way inherently mutually exclusive. 
     The drawings featured in the figures are provided for the purposes of illustrating some embodiments of the present invention and are not to be considered as a limitation thereto. Term “means” preceding a present participle of an operation indicates a desired function for which there is one or more embodiments, i.e., one or more methods, devices, or apparatuses for achieving the desired function and that one skilled in the art could select from these or their equivalent in view of the disclosure herein and use of the term “means” is not intended to be limiting. 
     Referring to  FIGS.  1 - 4 , and  5 A- 7 B , a versatile clamp assembly  100  generally useful for securing one or more devices to a structure comprises a mounting body  101  with a slot  102  adapted to receive an edge of the structure such as a variety of standing seam profiles of a metal roof so as to be secured thereto by a fastener assembly  104 . As demonstrated in the embodiment shown in  FIG.  5 A  and the alternative embodiment of  FIG.  5 B , mounting body  101  may be formed from a body base  160  of a predetermined shape that may be formed generally in an open loop shape, or other shape having a generally circular form, e.g., a G-shape, thereby forming a slot for receiving the raised portion formed the mounting body attaching the clamp assembly thereto. Body base  160  may take any suitable shape in terms of number of sides and individual dimension of each segment thereof. For example, body base  160  may include a device base segment  161  including a first arm base segment  163   a  disposed at one end, and a second arm base segment  163   b  disposed at the other end thereof. A fastener base segment  164  may extend outwardly from the first arm base segment  163   a  at an angle θ, and an abutment base segment may extend inwardly from the second arm base segment  163   b . Angle θ may be any suitable acute or obtuse angle; however as illustrated herein, θ is about 80 degrees, and is adapted for positioning a fastener assembly  104  to allow for convenient access of a tool and/or to provide for a larger internal clearance, such as to provide a larger passage  180 , which will be described further below. In a similarly manner, abutment segment may be disposed at an acute or obtuse angle with respect to a first angled base segment  162   a  may couple the device base segment  161  to the first arm base segment  163   a . Similarly, a second angled base segment  162   b  may couple the device base segment  161  to the second arm base segment  163   b.    
     Referring to  FIGS.  1 - 4  and  5 A- 5 B , body base  160  forms the predetermined shape that defines the mounting body  101 , which is adapted to receive or otherwise couple to standing seams of different profiles, as well as to other things, thereby making a versatile clamp assembly  100 . Mounting body  101  may be formed having a variety of thicknesses corresponding to the various segments of body base  160 , or mounting body may be formed having a substantially uniform thickness therealong. For example, appropriate thickness(es) may be selected to reduce cost and ensure adequate strength and holding capability of the mounting body  101 . Extending outwardly from each of these segments may be the actual surfaces of the mounting body  101 , and they are described herein in kind. In this way, an upper portion  170  and an inner portion  171  may be offset from the device base segment  161 , wherein the upper portion  170  may be configured to couple to a device, and the inner portion  171  may be configured to couple to a portion of the edge, that is in this embodiment a standing seam  103 . First and second arm portions  173   a  and  173   b  may form the inner surfaces offset inwardly from first and second arm base segments  163   a  and  163   b , respectively. First and second angled portions  172   a  and  172   b  may be formed between and couple each of the inner portion  171  on one side and first arm portion  173   a , and the inner portion  171  on the other side and second arm portion  173   b . The fastener base segment  164  may include a fastener base portion  174 , wherein one or more push-pin openings  107  and a fastener opening  111  may be formed and extend through to the first arm portion  173   a . Then, abutment base segment  165  may comprise a leg portion  175 , an abutment portion  176 , and a sloped surface  177 , which is sloped in the direction of force to direct engagement of pins  105 . Formed on and/or within the abutment portion  176  may be one or more pockets  120 , such as a dimple shape, corresponding to each of the one or more pins  105  extending through said one or more push-pin openings. The one or more pockets  120  are configured to cooperate with the one or more pins  105  for increasing the holding force of the clamp assembly  100 , whereby in operation tightening the fastener  109  of the fastener assembly  104  urges the one or more pins  105  against the standing seam  103  causing indentation or recess in the standing seam  103 . 
     The clamp assembly  100  includes a fastener assembly  104  comprising a plurality of pins  105  that can be urged against the standing seam  103  in a non-rotating manner by tightening the fastening element  109  which transmits force to the ends  106  of pins  105  by pressing on the washer  108 . The pins advantageously hold the mounting body  101  to the standing seam  103  with an evenly distributed holding force. The pins  105  align with pockets  120  on the abutment portion  176  allowing for slight deformation of the standing seam  103  into the pockets  120 . The pin  105  and pocket  120  arrangement thereby improves securing and maintaining the purchase of the clamp assembly  100  to the standing seam  103  under adverse thermal, vibration, seismic, wind and other environmental conditions without deforming or twisting the raised seam  103  or roof. The pins  105  have ends  106  that may be flat or shaped, such as tapered ends  106  as shown herein. Shaped ends may have, for example, rounded, domed or tapered profiles. Smooth pin ends accomplish an object of the present invention which is to maintain the integrity of the surface paint, powder coat, Teflon, or other protective coating thereby avoiding cosmetic and/or structural imperfections due to the installation process and/or environmental stresses. The use of pins  105  in the clamp assembly  104  also eliminates manufacturing steps and cost such as, for example, the threading of holes of two or more set screws. 
     In operation, the pins  105  are urged against a standing seam  103  to a closed position by a washer  108  and a fastening element  109  with a locking portion  110 . The washer  108  may be a flat washer or crush washer of suitable material, such as, for example, 300 Series Stainless Steel, and dimensioned 1″ inch outer diameter and ⅜ inch inner diameter with a thickness of approximately 0.005″-0.075″ inches. In an alternative embodiment, the fastening element  109  can be formed with an integral washer  108 , or yet alternatively an integral washer  108  and locking portion  110 . In operation the washer  108  may crush or deform under the torque and tightening of the fastening element  109 . The washer  108  can deform on both surfaces: deforming or scoring the washer  108  by the operation of rotating against the ends of the pins  106  thereby forming a unique groove or channel; also simultaneously deforming on the other surface adjacent the locking portion  110  of the fastening element  109 . In this manner, the present invention overcomes disadvantages of prior art systems where re-torquing and retightening of set screw fasteners is recommended and/or required. 
     The fastener  108  can be a flange head cap screw of suitable material, such as, for example, 300 Series Stainless Steel. The fastening element  109  has a locking portion  110  integrated on a surface adjacent the washer  108  or a surface that otherwise engages with the washer  108 . In operation, torquing or tightening the fastening element  109  pushes on the washer  108  and on the ends  106  of the pins  105 , thereby deforming the washer  108  as the locking portion  110  and pins  105  dig into the surface of the washer  108 . The fastening element  109  operates to move the fastener assembly  104  between open and closed positions. The closed position in this context refers to when the pins  105  are securely engaged with the standing seam  103 . 
     The various embodiments contemplated herein of the clamp assembly  100 , according to the present invention, may or may not employ either or both of the first and second angled base segments  162   a ,  162   b , i.e., the corresponding first and second angled portions  172   a  and  172   b . Similarly, the inner portion  171  may be characterized by a single continuous flat or contoured surface extending between first and second arm portions  173   a  and  173   b , such as in the embodiment shown in  FIGS.  5 B,  6 B, and  7 B . Alternatively, inner portion  171  may be characterized by a plurality of flat and/or contoured surfaces extending between first and second arm portions  173   a  and  173   b , such as in the embodiment shown in  FIGS.  1 - 4 ,  5 A,  6 A, and  7 A . Additionally, sloped portion  177  may or may not be employed. When employed, sloped portion  177  may be disposed inwardly, such as in the embodiment shown in  FIGS.  5 B,  6 B, and  7 B , or outwardly, as in the embodiment shown in  FIGS.  1 - 4 ,  5 A,  6 A, and  7 A . Furthermore, upper surface  170  may or may not comprise an attachment opening  121 , adapted for coupling a device to the structure via the clamp assembly  100  and standing seam  103 . Upper surface  170  may be adequately shaped, either substantially flat or contoured, to support a device under the force of gravity. 
     As previously described, clamp assembly  100  comprises, according to the present invention, the various segments of body base  160  corresponding to portions including at least upper and inner portions  170 ,  171 , first and second arm portions  173   a ,  173   b , fastener base portion  174 , leg portion  175  and abutment portion  176  that create a slot  102 , which is generally adapted for clamping to standing seams  103  having a variety of profiles and provide secure coupling of one or more devices thereto. As represented in  FIGS.  5 A and  5 B , abutment portion  176  and second arm portion  173   b  define a body entry  166 , which defines the opening to slot  102 , and is sized to accommodate shapes and seam profiles common to, e.g., the architectural industry. Furthermore, in an open position, approximately as represented in partially-exploded view of  FIG.  2   , tapered ends  106  of pins  105  may be fully retracted within pin openings  107 , and similarly the threaded  112  portion of fastening element  109  within fastener opening  111  such that the full dimension of body opening  166  may be utilized to accept a head of a standing seam within slot  102 . Once the clamp assembly is in position with respect to the intended location on the standing seam  103 , fastener assembly  104  may be advanced via tightening of fastener element  109 , with linear translation of the pins  105  through pin openings  107  wherein the force of the fastener element  109  is transmitted to the pins  105  through washer  108 . Fastener element  109  may include locking portions  110  to inhibit retraction of the fastener once assembled and/or secured about the seam  103 . 
     In the embodiment represented in  FIGS.  6 A and  6 B  according to the present invention, clamp assembly  100  is shown in an approximate closed position about seam  103 .  FIG.  6 A  represents a standing seam  103  having a bulb-style profile, and  FIG.  6 B  represents a standing seam  103  having a T-panel profile. In an alternative embodiment represented in  FIGS.  7 A and  7 B  according to the present invention, clamp assembly  100  is shown in an approximate closed position about seam  103 .  FIG.  7 A  represents a standing seam  103  having a bulb-style profile, and  FIG.  7 B  represents a standing seam  103  having a T-panel profile. Regardless of the embodiment, deformation of the panel may or may not be perceptible to the naked eye, especially when the clamp is engaged thereon, and therefore the figures herein illustrating the closed position are for representative purposes. Body entry  166  can be seen to be sized accordingly to allow entry of either the blub-style or the T-panel profiles. In one embodiment, the body entry  166  is dimensioned to approximately 1″ (inch), but may be larger or smaller sized as appropriate for the intended application and/or field of use. The one or more pins  105  may be about 2.1″ (inches) in length and about 5/16″ (inch) in diameter, and may also be sized as appropriate. Clamp assembly  100  according to the present invention may be adapted for coupling a device to any profile standing seam, including, but not limited to: trapezoidal panel, butler panel, double lock panel, snap lock panel, snap lock short panel, single lock panel, butler panel, T-panel, bulb-style panel, and/or zip rib panel. The aforementioned angle θ may be selected to accommodate a particular profile, for example an angle θ of about 80 degrees, which may be adapted for larger profiles, such as for the bulb-style or T-panel profiles. 
     The selection of at least upper portion  170 , inner portion  171 , first and second angled portions  172   a ,  172   b , first and second arm portions  173   a  and  173   b , fastener base portion  174 , leg portion  175 , abutment portion  176 , and sloped portion  177  may be selected and/or dimensioned to provide the structural support necessary to securely couple a device to a standing seam  103 , as well as to reduce cost in parts of clamp assembly  100 . For example, as previously mentioned, body entry  166  may be sized to accommodate larger-dimensioned heads and/or ends of standing seams  103 . Also, the linear distance between first and second arm portions  173   a  and  173   b  may be selected to accommodate larger- or smaller-shaped profiles. Additionally, anchor portions, e.g., points, may be formed along one or more surfaces of clamp assembly  100 , such as inner portion  171 , abutment portion  176 , and tapered end  106  of one or more pins  105 , as shown representatively in  FIGS.  5 A- 7 B . 
     In another advantage according to the present invention, clamp assembly  100  when in an assembled, i.e., closed, position about standing seam  103  provides one or more passage portions  180 , determined according to the free space adjacent the clamp assembly  100  and seam  103 , for the holding of items and things, such as cable  190 , shown representatively as a cross-section in  FIG.  6 B . According to the embodiment shown in  FIGS.  6 A and  7 A  for example, two passage portions  180  are formed proximate either lateral side of the standing seam  103 . As another example in  FIG.  6 A , four passage portions  180  are formed above and below the T, and as a final example shown in  7 B, two passage portions  180  are formed. 
     Devices for coupling via clamp assembly  100  to one or more standing seams  103  include, but are not limited to panels, solar panels, snow rails, wind clamps, signs, HVAC equipment, conduit, and the like to a metal roof. The attachment opening  121  may be threaded so as to accept a threaded fastener or smooth so as to accept a self-tapping fastening element (e.g. self-tapping bolt, screw, etc.) which then serves to attach the device to the mounting body  101 . The mounting body  101  may be formed from metal or metal alloys such as stainless steel, aluminum, aluminum alloys such as 6061-T6, or other materials with suitable strength and resistance to environmental conditions. The body base  160  and corresponding elements of the mounting body  101  may be manufactured from, for example, extruded stock. The longitudinal dimension of the mounting body  101 , e.g., out-of-plane in  FIG.  5 A , may be formed by cutting an extruded bar, having the cross-sectional shape described herein, to a desired length for a particular application. Each of the various openings, such as the push-pin openings  107 , the fastener opening  111 , and the attachment opening  121 , can be formed in the mounting body  101  by computer numeric controlled (CNC) machining, milling or other suitable manufacturing process. The mounting body  101  and/or the one or more pins  105  may be deburred, i.e., removal of sharp edges, such as by using a vibratory tumbler to remove the burrs and sharp edges that can damage the surface or coating of a standing seam  103 . 
     While certain configurations of structures have been illustrated for the purposes of presenting the basic structures of the present invention, one of ordinary skill in the art will appreciate that other variations are possible which would still fall within the scope of the appended claims. Additional advantages and modifications will readily occur to those skilled in the art. Therefore, the invention in its broader aspects is not limited to the specific details and representative embodiments shown and described herein. Accordingly, various modifications may be made without departing from the spirit or scope of the general inventive concept as defined by the appended claims and their equivalents.