Patent Abstract:
Clamp assemblies for mounting solar panels and accessories. Clamp assemblies can have geometric features, shaped apertures for fasteners, and measured protrusions for allowing clamp rotation, lateral adjustment, self-alignment, and angled surfaces for facilitating installation of a solar panel.

Full Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application claims priority to U.S. Provisional application No. 62/066,240, filed on Oct. 20, 2014, which is entitled “SELF-ALIGNING CLAMPS FOR SECURING SOLAR ENERGY PANELS,” to U.S. Provisional application No. 62/066,243, filed on Oct. 20, 2014, which is entitled “METHOD OF INSTALLING A ROOF FLASHING,” and to U.S. Non-provisional application Ser. No. 14/887,231, filed Oct. 19, 2015, which is entitled “CLAMPS FOR SECURING SOLAR ENERGY PANELS,” each of which are expressly incorporated by reference herein in their entireties. 
     
    
     TECHNICAL FIELD 
       [0002]    The present technology pertains to solar panel mounts, and more specifically pertains to self-aligning clamps for securing solar energy panels. 
       BACKGROUND 
       [0003]    As solar energy becomes more economical to produce electricity for direct consumption, more solar energy systems are being installed on rooftops. Typically, components of the solar energy systems such as solar panels are installed using conventional mounting structures. However, conventional mounting structures typically require precise dimensions and can result in excessive material and extensive installation time. 
       SUMMARY 
       [0004]    Additional features and advantages of the disclosure will be set forth in the description which follows, and in part will be obvious from the description, or can be learned by practice of the herein disclosed principles. The features and advantages of the disclosure can be realized and obtained by means of the instruments and combinations particularly pointed out in the appended claims. These and other features of the disclosure will become more fully apparent from the following description and appended claims, or can be learned by the practice of the principles set forth herein. 
         [0005]    Some embodiments of the present technology involve a clamp assembly for mounting solar panels and accessories. The clamp assemblies can include a top clamp with a substantially planar plate, raised flanges that extend away from the plate in opposite directions than the first raised flange; a geometric protrusion extending downward from the plate, and an aperture disposed through the plate and the geometric protrusion. The geometric protrusion of the top plate mates with a geometric cavity in a bottom clamp so that the top and bottom clamps self-align, thereby facilitating installation of a solar panel. 
         [0006]    The bottom clamp can involve a base member having the geometric cavity disposed therein, flanges extending away from a lower surface of the base member in opposite directions and a bottom clamp aperture extending through the base member. The base member can also involve a geometric cavity in its top surface. 
         [0007]    The top clamp and the bottom clamp are configured to freely rotate about a fastener inserted through the top clamp aperture and the bottom clamp aperture. However, when compressed enough, the geometric protrusion of the top plate mates with a geometric cavity in a bottom clamp so that the top and bottom clamps self-align. Also, in some embodiments, the top clamp aperture and the bottom clamp aperture are configured as a slot for allowing the top clamp and bottom clamp to adjust laterally without moving the fastener when the fastener is fixed to a particular location. The free rotation, the self-alignment, and the ability to laterally adjust the clamps are some of the features that facilitate installation of a solar panel. 
         [0008]    The clamp assembly can include protrusions in the bottom clamp that act as a fulcrum for reducing toque on a fastener and for defining additional clamping surfaces for solar panel accessories, etc. 
         [0009]    In some embodiments of the present technology, top and bottom flanges are substantially symmetrical on either side of the assembly, thereby enabling universal clamps. In some embodiments, the one base flange is angled upward toward the top clamp such that a solar panel can be inserted between the top clamp and the bottom clamp at an angle, thereby facilitating installation. 
         [0010]    The clamp assembly can include various grooves for increasing the friction on a solar panel clamped between the top clamp and the bottom clamp, spikes for piercing an anodization layer of a solar panel clamped between the top clamp and bottom clamp for electrically bonding and grounding the clamp assembly and the solar panel. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0011]    In order to describe the manner in which the above-recited and other advantages and features of the disclosure can be obtained, a more particular description of the principles briefly described above will be rendered by reference to specific embodiments thereof which are illustrated in the appended drawings. Understanding that these drawings depict only exemplary embodiments of the disclosure and are not therefore to be considered to be limiting of its scope, the principles herein are described and explained with additional specificity and detail through the use of the accompanying drawings in which: 
           [0012]      FIG. 1  is an isometric view of a clamp assembly representing one example of the present technology; 
           [0013]      FIGS. 2A and 2B  are end views depicting the self-aligning action of the clamp assembly representing one example of the present technology; 
           [0014]      FIGS. 3A and 3B  are end views showing one and two solar energy panels engaging with the clamp assembly representing one example of the present technology; 
           [0015]      FIG. 4  is an end view depicting an accessory being clamped in a secondary clamping location representing one example of the present technology; 
           [0016]      FIG. 5A and 5B  is a perspective view showing a sheet metal type lower clamping surface representing one example of the present technology; 
           [0017]      FIG. 6  illustrates a side view of an asymmetrical clamp assembly according to some embodiments of the present technology; 
           [0018]      FIGS. 7A and 7B  illustrate views of an asymmetrical clamp assembly having solar panels installed therein according to some embodiments of the present technology; 
           [0019]      FIG. 8A  illustrates an example a bridge clamp assembly according to some embodiments of the present technology; 
           [0020]      FIG. 8B  illustrates a top view of a matrix of solar panels which are supported and secured together using clamp assemblies and bridge clamp assemblies according to some embodiments of the present technology; and 
           [0021]      FIG. 9  illustrates a side view of another clamp assembly according to some embodiments of the present technology. 
       
    
    
     DESCRIPTION 
       [0022]    Various embodiments of the disclosure are discussed in detail below. While specific implementations are discussed, it should be understood that this is done for illustration purposes only. A person skilled in the relevant art will recognize that other components and configurations may be used without parting from the spirit and scope of the disclosure. 
         [0023]    As explained above, conventional solar panel mounting structures require precise dimensions and can result in excessive material and extensive installation time. Accordingly, the present technology involves mounting clamps and mounting bridges that facilitate solar panel mounting and installation. 
         [0024]    Some embodiments of the present technology involve self-aligning clamp assemblies configured to secure solar energy panels to a fixed body. The clamp assemblies can consist of a bottom clamp, a top clamp, and a fastener, such as a bolt and nut, to compress the top clamp and bottom clamp together. 
         [0025]    The self-aligning clamp assemblies can be specifically designed to support solar energy panels, solar energy panel frames, etc. A bottom clamp can support one or more solar energy panels from downward forces, such as gravity, positive wind pressure, snow loading, or other forces that push the solar energy panel towards Earth. The top clamp, being held in place with a fastener to the bottom clamp, can prevent one or more solar energy panels from upward forces, such as a difference in air pressure that would pull upwards on the solar energy panel. When the bottom clamp and top clamp are compressed together on one or more solar energy panels, the clamps additionally prevent the solar energy panels from moving laterally. The clamp assembly can be secured to a fixed connection point on an installation surface using its own fastener, or with a secondary fastener, as explained in greater detail below. In some embodiments of the present technology, the clamps each have two clamping surfaces on opposite sides of a fastener, such that one or more solar energy panels can engage on both sides of each clamp. 
         [0026]      FIG. 1  is an isometric view of the clamp assembly  101  including of a top clamp  106 , a bottom clamp  108 , and a fastener  103 . The fastener  103  may consist of a fastener bolt  104  and a fastener nut  105 , and fastener bolt  104  extends through apertures  113   a,    113   b  in the top clamp  106  and bottom clamp  108 , respectively. Apertures  113   a,    113   b  may be circular in shape (i.e. a hole) or a slot shape, as shown in  FIG. 1 . Turning the fastener nut  105  relative to the fastener bolt  104  will cause the fastener nut  105  and fastener bolt  104  to compress together, thereby compressing together the top clamp  106  to the bottom clamp  108 . 
         [0027]    The top clamp  106  can have an offset flange  102  that protrudes horizontally away from the body of the clamp. The lower surface of offset flange  102  can be substantially parallel with the top surface of the top clamp  106 . Alternatively, the lower surface of offset flange  102  can be at an angle with the main top surface of the top clamp  106  such that, when the top clamp  106  is compressed to the solar energy panel (not shown), the top clamp  106  deflects under stress and the clamping surface is drawn down to be parallel with the top surface of the solar energy panel. 
         [0028]    The bottom clamp  108  can have of a main body with one or more horizontal flanges  110 . As depicted in  FIG. 1 , bottom clamp  108  is symmetrical in shape and has a horizontal flange  110  on both sides of fastener  103  in order to capture multiple solar energy panels. These horizontal flanges  110  act as the lower clamping surface on a solar energy panel (not shown). The horizontal flanges  110  can also be the same size and shape to make the bottom clamp  108  symmetrical in shape. This has the benefit of universality, whereby either horizontal flange  110  can be used first in the installation process, making the clamps easier to use. 
         [0029]    Horizontal flange  110  may have lips  111   a,    111   b  on its outward edge in order to help capture a solar energy panel and to prevent the solar energy panel from readily sliding off of the horizontal flange  110  (i.e. the clamping surface). Also, the horizontal flanges  110  can have bottom clamp grips  112   a,    112   b  may be a textured surface, grooved surface, or similar gripping feature to help hold a solar energy panel from moving when compressed by the top clamp  106  and bottom clamp  108 . 
         [0030]    Additionally, the horizontal flanges  110  can have a channel  115   a,    115   b  traversing a lengthwise orientation with the module to fit a sheet metal part (not shown). This sheet metal part can have sharp spikes protruding upward and/or downward to cut a coating, such as anodization or paint, on the bottom clamp and/or the solar energy panel, thereby electrically bonding and grounding the two components together. The horizontal flange can have vertically protruding spikes (not shown) to penetrate the anodization layer of a solar energy panel with the purpose of creating an electrical grounding and bonding path. These spikes can be a separate component press or screw fit into a hole in the horizontal flange, and can be a molded or extruded as an integral feature of the horizontal flanges  110 . 
         [0031]    As explained above, the top clamp  106  and bottom clamp  108  can have apertures  113   a,    113   b  passing there through to allow a fastener  103  to pass through. The aperture can be a hole, slot, aperture or similar cut-out. A slot can be beneficial as it allows the top clamp  106  and bottom clamp  108  to adjust laterally (along the z-axis) without moving the fastener  103 , which can be fixed to a particular location. 
         [0032]    Also, the top clamp  106  and the bottom clamp  108  can each consist of a single shape throughout their length (along the z-axis), allowing for manufacturing using an extrusion process which can be less expensive than other forms of manufacturing and allowing for universality during installation of a solar energy panel to the clamps  106 ,  108 . 
         [0033]    In some embodiments of the present technology, the top clamp  106  has a centrally positioned downward top clamp protrusion  107 . This protrusion can be substantially trapezoidal, triangular, or square in shape, and can extend the entire length of the top clamp. The top clamp protrusion  107  engages with a similarly positioned bottom clamp cavity  109  on the top surface of the bottom clamp  108 . As the top clamp  106  and bottom clamp  108  are drawn closer together, the top clamp protrusion  107  resides within the bottom clamp cavity  109  to prevent the two clamps from rotating relative to one another around the fastener. This ensures the two clamp pieces are substantially aligned with one another to provide even clamping surfaces on a solar energy panel. As shown in  FIG. 1 , the top clamp protrusion  107  can nest into bottom clamp cavity  109  as the top clamp  106  and bottom clamp  108  are drawn towards one another. 
         [0034]      FIG. 2A  depicts the top clamp  106  rotated some arbitrary amount relative to bottom clamp  108  around fastener  103  such that the end edges of both clamps are not parallel. As top clamp  106  approaches bottom clamp  108 , an edge of top clamp protrusion  107  may contact an edge of bottom clamp cavity  109  at location  201 . In one example of the present invention as shown in  FIG. 2A , the top clamp protrusion  107  and bottom clamp cavity  109  are substantially trapezoidal in shape. In  FIG. 2B , top clamp  106  has approached closer to bottom clamp  108 , and the trapezoidal shape of top clamp protrusion  107  has slide along the surface of bottom clamp cavity  109 , thereby rotating top clamp  106  so that the end edge of top clamp  106  is now substantially parallel with the end edge of bottom clamp  108 , thereby reducing the need for positioning the clamps as they are compressed together during the installation on a solar energy panel. 
         [0035]      FIG. 3A  depicts an end view of clamp assembly  101  with solar energy panel frame section  301  clamped in one side between top clamp  106  and bottom clamp  108 . 
         [0036]    In some embodiments of the present technology, the bottom clamp  108  can have two vertical protrusions  302 ,  303  on its topmost surface symmetrically located to either side of the cavity. When a solar energy panel frame section  301  is clamped between the sides of a top clamp  106  and bottom clamp  108 , and the top clamp  106  is compressed towards the bottom clamp  108  using the fastener  103 , the vertical protrusion furthest from the solar energy panel ( 302  in  FIG. 3A ) can be designed prevent the top clamp  106  from being tightened so much that the top clamp would exert too much torque on the fastener  103  when another solar energy panel is not installed on the opposite side. 
         [0037]    The vertical protrusions  302 ,  303  can be dimensioned above the top surface of the horizontal flanges  110  such that the angle of articulation of the top clamp  106  around the fulcrum is great enough to maintain a clearance space  316  between the top clamp  106  and bottom clamp  108 , yet small enough so not to impose permanent damage to the fastener  103  from bending. Also, the top clamp  106  will not be perfectly parallel with the bottom clamp  108  when the top clamp  106  is compressed to the solar panel frame section  301  using the fastener  103 , however the angle created will not be so great as to substantially damage the fastener  103 . 
         [0038]    The overall height of bottom clamp  108  and vertical protrusions  302  and  303  may depend on the height of frame section  301 , meaning a frame section of a different height may require a bottom clamp and vertical protrusion of a also a different height. Vertical protrusions  302  and  303  may be the same height and position on bottom clamp  108  in order to maintain universal functionality should a solar energy panel be installed on the opposite side compared to the orientation in  FIG. 3A . The clamping surface on offset flange  102  may be at an acute angle relative to the vertical plane of the clamp assembly  101 . This feature allows for the clamping surface to be relatively parallel with the top of the frame section  301  when the top clamp  106  articulates around frame section  301  as it is compressed down. 
         [0039]      FIG. 3B  depicts the assembly in  FIG. 3A  with the addition of a second frame section  305 . In some embodiments, as shown in  FIG. 3B , the dimensions of the components are configured such that when solar panel frame sections  301 ,  305  are located on both sides of clamp assembly  101 , and the top clamp  106  is compressed towards the bottom clamp  108  using the fastener  103 , the vertical protrusions  302 ,  303  do not interfere with the top clamp  106  and a clearance space  317  can be maintained between the top clamp  106  and bottom clamp  108  such that pressure from tightening the fastener is transferred to the solar energy panels  301 ,  305  and not to the vertical protrusions  302 ,  303 . Also, in these configurations, the top clamp  106  and bottom clamp  108  can be substantially parallel to one another when compressed together using the fastener  103 . 
         [0040]    Also, as shown in  FIGS. 3A and 3B , the clamping surfaces of the top clamp  106  can have substantially triangularly shaped sets of grooves  304   a,    304   b  or a textured surface that help induce additional friction on the solar energy panel to prevent it from moving when compressed by the top and bottom clamp. 
         [0041]      FIG. 4  depicts a side view of a clamp assembly  101  with gaps  401   a,    401   b  of a particular height and depth between the lower surface of the top clamp  106  and the upper surface of the bottom clamp  108 . The gaps  401   a,    401   b  can be used as a second clamp for accessories, such as a formed piece to sheet metal that angles downward to restrict air movement under a solar energy panel, an electrical connections box, electrical conduit, or similar accessories. The accessories can have a horizontal tab that can be placed in the gaps  401   a,    401   b  to secure the accessory to the clamp assembly. When the tab of an accessory is placed in the gaps  401   a,    401   b  and the fastener  103  tightened to compress the top clamp  106  towards the bottom clamp  108 , the top clamp  106  may press down on the accessory&#39;s tab and not on the vertical protrusion furthest from the solar energy panel. The accessory tab causes the top clamp  106  to behave similar to as if two or more solar energy panels are on both sides of the clamp assembly  101 . The surfaces of the top clamp  106  and bottom clamp  108  creating the gap can be textured and can have grooves cut in place to increase friction on an accessory&#39;s tab. The vertical protrusion of the bottom clamp  108  may act as a wall to prevent the accessory&#39;s tab from sliding too far in between the top and bottom clamps. 
         [0042]    In some embodiments of the present technology, a shaped plate is clamped in the gaps  401   a,    401   b  between the top clamp  106  and bottom clamp  108 , and extends downward towards an installation surface over which the solar energy panels reside. One purpose of the plate is to deflect airflow over one or more solar energy panels, reducing pressures on the underside of the solar energy panels. Another purpose is to deflect flame over one or more solar energy panels and prevent a fire from spreading to under one or more solar energy panels. The plate can have one or more bends in it to conform to the top clamp  106  and bottom clamp  108 , and bend to rest on the outer edge of the bottom clamp&#39;s  108  horizontal flange  110 . 
         [0043]    In  FIG. 4 , a clamp assembly  101  has a solar energy panel frame section  301  engaged on one side, and wind deflector  402  engage on an opposing side. In this example embodiment, the gap  401   a  is created between the top clamp  106  and bottom clamp  108  when the two pieces are compressed onto the frame section  305  and the top and bottom clamp remain substantially parallel with one another. The gap  401   a  may have a textured or grooved surface  404  to aid in gripping any component that may be clamped, such as wind deflector  402 . Wind deflector  402  has a thickness such that the compressive forces from the top and bottom clamp will be placed on the wind deflector  402 , and not on vertical protrusions  302  and  303 . Vertical protrusion  302  also acts as a guide to prevent installing the wind deflector  402  too far into the gap  401   a.  Other accessories, such as an electrical wiring box, wiring conduit clip, electronic inverter, or weather station, may have a tab that can be clamped in the gap  401   a  in a similar method to that of the wind deflector  402 . In one example of the present invention, wind deflector  402  has one or more bends to reduce the horizontal distance occupied when achieving a desired height. In some embodiments of the wind deflector  402 , these bends may sum to an angle less than  90  degrees, thereby allowing multiple wind deflectors to snuggly nest upon one another for packaging and shipping. The wind deflector  402  may bend around the outer edge of horizontal flange  110  at point  403 . In this example, the wind deflector is supported at both gap  401  and point  403 . 
         [0044]    Those with ordinary skill in the art having the benefit of this disclosure will appreciate that a wide variety of materials can be suited to carry out the present technology. In some embodiments of the present technology, the bottom clamp is formed of a sheet metal, a composite material, etc.  FIG. 5A  illustrates a self-aligning clamp according to some embodiments of the present technology.  FIG. 5A  illustrates a clamp assembly  500  with a sheet metal bottom clamp  501  having an upper plate  502  resting on lower plate  503  and assembled together to a top clamp  508  with a fastener through an aperture  504 . 
         [0045]    When the bottom clamp  501  has a substantially rigid structure, meaning the horizontal flanges deflect significantly less in proportion to the deflection of a solar energy panel when under downward force, point stresses can build up on the solar energy panel at the edge of the bottom clamp. To prevent this stress build-up, the horizontal flanges of the bottom clamp  501  are used to bend downward a particular amount as the solar energy panel deflects, with the purpose being to reduce point stresses on the solar energy panel at the edge of the bottom clamp. A design pointing stresses between the horizontal flanges and the solar energy panel tapers the horizontal flanges as they extend along the length of the solar energy panel. This tapered feature reduces point stress induced on the solar energy panel or the solar energy panel frame by the bottom clamp as a downward force is applied to the solar energy panel. 
         [0046]    As shown in  FIG. 5A , the upper plate  502  and lower plate  503  can flex independently of one another when exposed to downward force and can have tapered ends  505  to reduce in cross sectional area as they extend away from the center of the sheet metal bottom clamp  501 , yielding a non-linear deflection at the points of the tapered ends  505  as compared to the main body of the sheet metal bottom clamp  501 . This tapered feature reduces the point stress imposed on a solar energy panel when exposed to a downward force. Upper plate flange  506  protrudes a vertical distance below the top clamp to have a similar functionality as the vertical protrusions  302  and  303  described in  FIGS. 3A and 3B . Lower plate flange  507  extends vertically and exteriorly to upper plate  502 , and may be dimensioned to secure upper plate  502  to lower plate  503  via a press fit. Lower plate flange  507  has a width such that it will act as a guide similar to vertical protrusions  302  and  303  described in  FIG. 4 . Lower plate flange  507  may extend a height to coincide with the edge of the top clamp at point  508 . The lower plate flange  507  may therefore prevent the top clamp from rotating relative to the sheet metal bottom clamp  501 .  FIG. 5B  depicts gap  509  created between upper plate flange  506  and the top clamp. Gap  509  has the similar functionality as gap  401  described in  FIG. 4 . 
         [0047]      FIG. 6  illustrates a side view of another clamp assembly  600  according to some embodiments of the present technology. The clamp assembly  600  includes a top clamp  606  and a bottom clamp  608  secured together with a fastener  603  through apertures (not shown) in the top clamp  606  and bottom clamp  608  and a nut  699 . 
         [0048]    The top clamp  606  can have an offset flange  602  that protrudes horizontally away from the body of the clamp. Also, the bottom clamp  608  can have flanges  610 ,  611  on both sides of fastener  603  in order to capture multiple solar energy panels. According to  FIG. 6 , the flanges  610 ,  611  are asymmetrical and can serve independent purposes. The flange  611  can include a surface for supporting downward forces from a solar panel. Also the flange  611  can have one or more vertically protruding spike  612  to penetrate the anodization layer of a solar panel and create an electrical grounding and bonding path. 
         [0049]    The flange  610  can have an upward tilted configuration for allowing a solar panel to be slid between the top clamp  606  and bottom clamp  608  at an angle (as shown in  FIGS. 7A and 7B  below). In some embodiments, the flange  610  can be displaced (in the −y direction) when a solar panel is installed between the top clamp  606  and bottom clamp  608 . 
         [0050]    The bottom clamp  608  can also have a vertical protrusion  613  to prevent the top clamp  606  from being tightened, when a solar energy panel is installed on the opposite side, so much that the top clamp  606  would exert excessive torque on the fastener  603 , as explained in greater detail above in discussing  FIGS. 3A and 3B . Also, the vertical protrusion  613  can be dimensioned so as to create a gap  604  between the top clamp  606  and the bottom clamp  608  when they joined using the fastener  603 . The gap  604  can act as a secondary clamp (e.g. for accessories) as shown above in  FIG. 4 . The top clamp  606  and the bottom clamp  608  can each have a set of grooves  607 ,  609  facing each other in the gap  604  that help induce additional friction on the accessories. 
         [0051]      FIGS. 7A and 7B  illustrate views of a clamp assembly  700  with solar panels  750 ,  751  installed therein according to some embodiments of the present technology. As shown in  FIG. 7A , a solar panel  750  is clamped between top clamp  706  and the flange  711  of the bottom clamp  708 . The vertical protrusion  713  on its top surface of the bottom clamp  708  prevents the top clamp  706  from causing the fastener  703  to bend when a nut  799  is tightened down to secure the solar panel  750  in place. In other words, the vertical protrusion  713  maintains the top clamp  706  in a substantially parallel position relative to the bottom clamp  706  as the nut  799  is tightened down and only a solar panel  750  is in one side of the clamp assembly. 
         [0052]    Also, the flange  710  is configured at an angle or radius to allow solar panel  751  to be slide into the clamp assembly  700  when the solar panel  750  is already clamped therein. The angled flange feature allows an installer to serially install adjacent solar panels without having to loosen a previously tightened fastener and without having to bend over to uncomfortable and/or dangerous angles. 
         [0053]    As shown in  FIG. 7B , after the solar panel  751  is placed between the angled flange  710  and the top clamp and is articulated to an installation level, e.g. planar to the installation surface, level with the solar panel  750 , etc. In some embodiments of the present technology, the solar panel  751  displaces the flange  710 . Additionally, when the solar panel  751  is clamped into the clamp assembly  700 , the solar panel  751  applies upward force on the top clamp, thereby removing pressure on the protrusion  713  and more evenly distributing pressure onto the nut  799 . 
         [0054]    The clamps described in the present disclosure can be used to support solar energy panels on an installation surface. Additionally, the clamp assemblies can also be used to bridge adjacent solar energy panels.  FIG. 8A  illustrates an example of a bridge clamp assembly  800  according to some embodiments of the present technology. The bridge clamp assembly  800  includes a top bridge  806  and a bottom bridge  808  secured together with multiple fasteners  803   a,    803   b  through apertures  813   a,    813   b  and nuts  899   a,    899   b.  The bottom clamp  808  of the bridge clamp assembly  800  has asymmetrical flanges  810 ,  811  similar to the flanges  610 ,  611  and  710 ,  711  described above. In some embodiments, top bridge  806  and bottom bridge  808  have identical or substantially similar cross-sectional geometries as top clamp  710  and bottom clamp  711 . This allows for reduced manufacturing costs as the same profile shape can be used for multiple parts. 
         [0055]    The bridge clamp assembly  800  may also include multiple spikes  812   a,    812   b  to penetrate the anodization layer of a solar energy panel frame with the purpose of creating an electrical grounding and bonding path between adjacent solar panels. 
         [0056]      FIG. 8B  illustrates a top view of a matrix  850  of solar panels  852 ,  854 ,  856 ,  858  which are supported and secured together using clamp assemblies  860 ,  862 ,  864 ,  866 ,  868 ,  870  and which are further secured together using bridge clamp assemblies  872 ,  874 ,  876 . The clamp assemblies  860 ,  862 ,  864 ,  866 ,  868 ,  870  can include sharp spikes protruding upward and/or downward to cut a coating, such as anodization or paint, on the bottom clamp, top clamp and/or the solar energy panel, thereby electrically bonding and grounding the components and the panels and creating a grounding/bonding path between vertically coupled (indicated by the arrows in the y-direction) solar panels and clamp assemblies. Similarly, the bridge clamp assemblies  872 ,  874 ,  876  can have multiple spikes that penetrate the anodization layer of a solar energy panels, thereby electrically bonding and grounding the components and the panels and creating a grounding/bonding path between horizontally coupled (indicated by the arrows in the x-direction) solar panels and clamp assemblies. 
         [0057]    In some embodiments of the present technology, the top clamp and bottom clamp can be manufactured using an aluminum extrusion process having a good weight to strength ratio, while being less expensive than other processes. Additionally it allows for complex designs in one plane of each part. The top or bottom clamp can be manufactured using one or more stamped and formed pieces of sheet metal, (e.g. of aluminum or stainless steel). A stamped and formed process has the advantages of being cost effective while allowing different shapes and protrusions in three dimensions without a secondary machining operation. The top and bottom clamp can also be made of a composite material, a composite material molded over a reinforcing metal structure, etc. The composite material selection has the benefits of being electrically non-conductive, thereby reducing or eliminating the need to electrically ground and bond the top and bottom clamps to a solar energy panel or other metallic components. 
         [0058]      FIG. 9  illustrates a side view of another clamp assembly  900  according to some embodiments of the present technology. The clamp assembly  900  includes a top clamp  906  and a bottom clamp  908  that can be secured together with a fastener  903  through apertures (not shown) in the top clamp  906  and bottom clamp  908  and with a nut  999 . 
         [0059]    According to  FIG. 9 , the bottom clamp  908  has flanges  910 ,  911  on both sides of fastener  903  in order to capture multiple solar energy panels. The flange  911  can include a surface for supporting downward forces from a solar panel and a u-shaped groove  912  that can be configured to hold wires and that can be enclosed when a solar panel module  920  is clamped between the top clamp  906  and bottom clamp  908 . The flange  910  can also have a dipped groove  909  that acts as a recess to allow a solar panel to be installed between top clamp  906  and bottom  908  after fastener  903  has been tightened on a solar panel  920  has been installed. This process of installation is described in  FIG. 7 . Flange  910  may have a curvature to on the top surface to more evenly distribute stresses induced when a solar panel (not shown) is installed. 
         [0060]    Although a variety of examples and other information was used to explain aspects within the scope of the appended claims, no limitation of the claims should be implied based on particular features or arrangements in such examples, as one of ordinary skill would be able to use these examples to derive a wide variety of implementations. Further and although some subject matter may have been described in language specific to examples of structural features and/or method steps, it is to be understood that the subject matter defined in the appended claims is not necessarily limited to these described features or acts. For example, such functionality can be distributed differently or performed in components other than those identified herein. Rather, the described features and steps are disclosed as examples of components of systems and methods within the scope of the appended claims.

Technology Classification (CPC): 7