Patent Publication Number: US-10770805-B2

Title: Clamp and clamp assembly

Description:
REFERENCE TO RELATED APPLICATION 
     This application is a continuation of prior-filed, co-pending U.S. patent application Ser. No. 15/187,572, filed Jun. 20, 2016, which claims the benefit of U.S. Provisional Patent Application No. 62/182,257, filed Jun. 19, 2015. The entire contents of these documents are hereby incorporated by reference. 
    
    
     BACKGROUND 
     The present disclosure relates to a connector that is connectable to a support structure, and particularly a connector for mechanically and electrically coupling a frame to a support structure. 
     SUMMARY 
     In one embodiment, a connector configured to mechanically and electrically couple a first frame to a second frame includes a body, a member, and a plurality of projections extending from the body and configured to contact at least one of the first frame and the second frame. The body includes a first end and a second end and defines a longitudinal axis extending between the first end and the second end. The body further includes a feature for engaging a fastener. The member is positioned adjacent the first end of the body and is configured to engage at least one of the first frame and the second frame. 
     In another embodiment, a connector configured to mechanically and electrically engage a support structure includes a first portion, a second portion coupled to the first portion, and an intermediate portion positioned between the first portion and the second portion. The first portion includes a distal end having a first plurality of projections. The second portion includes a distal end having a second plurality of projections. The intermediate portion couples the second portion to the first portion. 
     In yet another embodiment, a connector assembly configured to mechanically and electrically couple at least one frame to a support structure includes a first connector, a second connector, and a connector coupling the first connector to the second connector. The first connector includes a body, a member, and a plurality of projections extending from the body and configured to contact one of the at least one frame. The body includes a first end and a second end and defines a longitudinal axis extending between the first end and the second end. The body further includes a first aperture positioned between the first end and the second end. The member is positioned adjacent the first end of the body and is configured to engage one of the at least one frame. The second connector includes a first portion, a second portion coupled to the first portion, and an intermediate portion positioned between the first portion and the second portion. The first portion includes a distal end having teeth configured to engage the support structure. The second portion includes a distal end having teeth configured to engage the support structure. The intermediate portion couples the second portion to the first portion and includes a second aperture. 
     In still another embodiment, a connector is configured to mechanically and electrically couple a first frame to a second frame and including a body that has a longitudinal axis and an aperture that extends therethrough. The connector also includes a member that extends from a first end of the body, and a plurality of bonding projections that extend from the body. The member is configured to be coupled to one of the first frame or the second frame. 
     In still another embodiment, a connector is configured to mechanically and electrically couple to a support structure. The connector includes a body that has a longitudinal axis and a first portion that is coupled to a second portion by an intermediate portion therebetween. The intermediate portion includes an aperture extending therethrough and each of the first portion and the second portion include a surface having a plurality of projections extending therefrom. 
     In still another embodiment, a connector assembly is configured to mechanically and electrically couple adjacent frames to a support structure. The connector assembly includes a first connector configured to be coupled between a first frame and a second adjacent frame and a second connector configured to be coupled to the support structure. The first connector includes a body that has a longitudinal axis and an aperture that extends therethrough. The first connector also includes a member that extends from a first end of the body, and a plurality of bonding projections that extend from the body. The member is configured to be coupled to one of the first frame or the second frame. The second connector includes a body that has a longitudinal axis and a first portion that is coupled to a second portion by an intermediate portion therebetween. The intermediate portion includes an aperture extending therethrough and each of the first portion and the second portion include a surface having a plurality of projections extending therefrom. 
     Other aspects of the disclosure will become apparent by consideration of the detailed description and accompanying drawings. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a perspective view of a first connector. 
         FIG. 2  is a plan view of the first connector of  FIG. 1 . 
         FIG. 3  is an end view of the first connector of  FIG. 1 . 
         FIG. 4  is a side view of the first connector of  FIG. 1 . 
         FIG. 5  is a perspective view of a first connector according to another embodiment. 
         FIG. 6  is a plan view of the first connector of  FIG. 5 . 
         FIG. 7  is an end view of the first connector of  FIG. 5 . 
         FIG. 8  is a side view of the first connector of  FIG. 5 . 
         FIG. 9  is a perspective view of a second connector. 
         FIG. 10  is a plan view of the second connector of  FIG. 9 . 
         FIG. 11  is an end view of the second connector of  FIG. 9 . 
         FIG. 12  is a side view of the second connector of  FIG. 9 . 
         FIG. 13  is an enlarged perspective view of portion  13 - 13  of the second connector of  FIG. 9 . 
         FIG. 14  is a perspective view of a connector assembly including the first connector of  FIGS. 1-4  and the second connector of  FIGS. 9-13 . 
         FIG. 15  is a side view of the connector assembly of  FIG. 14 . 
         FIG. 16  is an end view of the connector assembly of  FIG. 14 . 
         FIG. 17  is a plan view of the connector assembly of  FIG. 14 . 
         FIG. 18  is a perspective view of a connector assembly including the first connector of  FIGS. 5-8  and the second connector of  FIGS. 9-13 . 
         FIG. 19  is a side view of the connector assembly of  FIG. 18 . 
         FIG. 20  is an end view of the connector assembly of  FIG. 18 . 
         FIG. 21  is a plan view of the connector assembly of  FIG. 18 . 
     
    
    
     DETAILED DESCRIPTION 
     Before any embodiments of the disclosure are explained in detail, it is to be understood that the disclosure is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the following drawings. The disclosure is capable of other embodiments and of being practiced or of being carried out in various ways. Also, it is to be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting. The use of “including,” “comprising” or “having” and variations thereof herein is meant to encompass the items listed thereafter and equivalents thereof as well as additional items. The terms “mounted,” “connected” and “coupled” are used broadly and encompass both direct and indirect mounting, connecting and coupling. Further, “connected” and “coupled” are not restricted to physical or mechanical connections or couplings, and can include electrical or hydraulic connections or couplings, whether direct or indirect. Also, electronic communications and notifications may be performed using any known means including direct connections, wireless connections, etc. 
       FIGS. 1-4  illustrate a first connector  10   a  including an elongated body  14 . In the illustrated embodiment, the body  14  has a substantially planar or flat portion defining a plane B (FIG. B). The body  14  includes a first end and a second end, and a first longitudinal axis A extends between the first end and the second end. An aperture  18  extends through the body  14  in a direction perpendicular to the axis A ( FIG. 2 ) and the plane B. A first clamping member  30  is positioned adjacent the first end of the body  14  and a second clamping member  34  is positioned adjacent the second end of the body  14 . The clamping members  30 ,  34  extend from the first and the second ends, respectively. In the illustrated embodiment, each clamping member  30 ,  34  is oriented at an acute angle  36  with respect to the longitudinal axis A. In some embodiments, the angle  36  is between approximately 55 degrees and approximately 85 degrees. In some embodiments, the angle  36  is approximately 59 degrees. In some embodiments, the angle  36  is approximately 80 degrees. 
     The first connector  10  includes one or more first bonding projections  40   a . In the embodiment of  FIGS. 1-4 , the first bonding projections  40   a  of the first connector  10   a  include a plurality of teeth  40   a  that extend from side edges of the body  14 . Stated another way, the body  14  includes side edges extending between the first end and the second end, and the teeth  40   a  protrude outwardly from the side edges in a direction perpendicular to the axis A. In the illustrated embodiment, each of the teeth  40   a  protrudes at an acute angle  44  with respect to the plane B ( FIG. 3 ) and relative to the axis A. The angle  44  is smaller than the angle  36  in the illustrated embodiment. In some embodiments, the angle  44  is between approximately 5 degrees and approximately 20 degrees. In some embodiments, the angle  44  is approximately 13 degrees. In some embodiments, there are twenty teeth  40   a  that extend from each side of the body  14 . In other embodiments there may be fewer or more teeth on each side. 
       FIGS. 5-8  illustrate a first connector  10   b  according to another embodiment. Some aspects of the first connector  10   b  is similar to the first connector  10   a  described above with respect to  FIGS. 1-4 . For the sake of brevity, only the differences between the first connector  10   b  and the first connector  10   b  are described in detail. Similar features are identified with similar reference numbers and may be identified with a “b” suffix instead of an “a” suffix. 
     As shown in  FIGS. 5-8 , the first bonding projections  40  of the first connector  10   b  include teeth  40   b  positioned on the ends of the body  14 . In the illustrated embodiment, each end includes a pair of teeth  40   b , and the teeth  40   b  of each end are positioned on each side of the clamping members  30 ,  34 . In addition, the teeth  40   b  on each end of the body  14  protrude from the first and the second ends at an acute angle  48  with respect to the plane B and relative to the axis A. In the illustrated embodiment, the angle  48  is smaller than the angle  36 . In some embodiments, the angle  48  is between approximately 5 degrees and approximately 20 degrees. In some embodiments, the angle  48  is approximately 17 degrees. 
     In the embodiment of  FIGS. 1-4  and the embodiment of  FIGS. 5-8 , the first connector  10   a ,  10   b  is symmetrical about the axis A. The first connectors  10   a ,  10   b  are also symmetric about an axis that is transverse to the axis A and parallel to the plane B. In some embodiments, the first connector  10   a ,  10   b  is manufactured from stainless steel. In other embodiments, the first connector  10   a ,  10   b  may be manufactured from another suitable material. 
     The first connector  10   a ,  10   b  of both the embodiment of  FIGS. 1-4  and the embodiment of  FIGS. 5-8  are configured to mechanically secure adjacent frames  50 A,  50 B (e.g., photovoltaics (PV) modules—see  FIGS. 14 and 18 ), and also to electrically bond or provide electrical communication between the frames  50 A,  50 B, each of which has a non-conductive coating of aluminum (e.g., oxide, paint, or anodization). In particular, the first clamping member  30  may engage or be coupled to a first PV module and the second clamping member  34  may engage or be coupled to a second PV module, while the first bonding projections (e.g., the teeth  40   a ,  40   b ) pierce the non-conductive coating of aluminum. Accordingly, the above-described first connectors  10   a ,  10   b  mechanically and electrically couple adjacent frames  50 A,  50 B, such as PV modules, to one another. 
     With respect to  FIGS. 14-21 , both of the first connector  10   a ,  10   b  described above can also be coupled to a claw member or second connector  100 . The components of the second connector  100  are described below. 
     Referring now to  FIGS. 9-13 , the second connector  100  includes a body  104 . The body  104  has a first end and a second end. A second longitudinal axis C ( FIG. 10 ) extends between the first end and the second end. In the illustrated embodiment, the second axis C is substantially parallel to the first axis A. The second connector  100  further includes a first portion  108  that is coupled to or integrally formed (i.e., formed as one piece) with a second portion  110 . In the illustrated embodiment, the first portion  108  and the second portion  110  are both integrally formed with an intermediate portion  112  therebetween. Each of the first portion  108  and the second portion  110  extend at an acute angle  114  relative to the intermediate portion  112 . An aperture  116  extends through the intermediate portion  112 . 
     As best shown in  FIGS. 12 and 13 , each of the first and the second portions  108 ,  110  includes a distal end with a hooked portion  130  having a leg  134  and a substantially U-shaped portion  138 . In the illustrated embodiment, the U-shaped portion  138  is oriented inwardly such that the U-shaped portion  138  of each hooked portion  130  curve toward one another. Each hooked portion  130  includes a terminal surface  142  with second bonding projections  146 . In the illustrated embodiment, the second bonding projections  146  include a plurality of teeth protruding from the terminal surface  142 . The surface  124  extends perpendicular to the longitudinal axis C ( FIG. 10 ). 
     In some embodiments, the second connector  100  is manufactured from stainless steel. In other embodiments, the second connector  100  may be manufactured from another suitable material. The second connector  100  is configured to engage a support structure (not shown) that is manufactured from aluminum, steel, or any other suitable metallic material. 
     As shown in  FIGS. 14-21 , a connector assembly  300  is formed by coupling one of the first connectors  10   a ,  10   b  to the second connector  100 . In the illustrated embodiment, the first connector  10   a  or  10   b  is coupled to and spaced apart from the second connector  100  by a fastener  200 . In the illustrated embodiment, the first longitudinal axis A of the first connectors  10   a ,  10   b  is parallel to the second longitudinal axis C of the second connector  100  when the connectors  10 ,  100  are coupled together. The fastener passes through the aperture  18  of the first connectors  10   a ,  10   b  and the aperture  116  of the second connector  100 . 
     The fastener  200  may be constructed from steel or another suitable metallic or electrically-conductive material. In some embodiments, the fastener  200  is a threaded fastener that is threadingly coupled to the second connector  100  (i.e., the aperture  116  may be threaded). In other embodiments, the fastener  200  is a rivet that couples the first connector  10  to the second connector  100 . In still other embodiments, the fastener  200  may be another type of fastener (e.g., a screw, a bolt, etc.). In still other embodiments, the first connectors  10  and the second connector may be coupled together in a difference manner. 
     In use, the connector assembly  300  couples adjacent PV modules to a support structure. For example, the portions  108 ,  110  of the second connector  100  are positioned in a channel or slot (not shown) on opposite sides of a rail of the support structure, and the bonding projections  146  or teeth pierce the rail. The second connector  100  extends away from the rail, providing a stand-off for the first connector  10 . The first connector  10  is spaced apart from the second connectors  100  and aligned with the second connector  100  along an axis X ( FIGS. 15 and 19 ). The first connector  10  is coupled between adjacent PV module frames, as discussed above. Once both the first connector  10  and the second connector  100  are appropriately positioned, the fastener  200  secures the first connector  10  to the second connector  100  and couples the PV module frame to the support structure. The connectors  10 ,  100  provide mechanical and electrical coupling between the adjacent PV modules, and between the PV modules and the support structure. 
     Although certain aspects have been described in detail with reference to certain preferred embodiments, variations and modifications exist within the scope and spirit of one or more independent aspects as described. Various features and advantages of the disclosure are set forth in the following claims.