Patent Description:
Current solar mounting solutions using rails as mounting structure use clamps to secure a solar module to the rail that can be cumbersome to install. Often, there is no securing mechanism to hold the clamp into the rail prior to the solar module being installed.

Further background information can be found from <CIT> which is directed to a rail and a solar module disposed on the rail and <CIT> which is directed to an attachment device which secures a structural component to a fastening rail having a slot-like opening.

Understanding that these drawings depict only exemplary embodiments of the disclosure and are not therefore 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:.

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. The embodiments of <FIG> are not encompassed by the wording of the claims but are considered as useful for understanding the invention.

<FIG> depicts an isometric view of the Clamp <NUM>. The Clamp <NUM> is an assembly of a Top Clamp <NUM>, a Spring <NUM>, a T-nut <NUM>, and a fastener <NUM>. The Clamp <NUM> is oriented in the X, Y, and Z cartesian coordinate planes <NUM>. The fastener <NUM> extends through one or more apertures in the Top Clamp <NUM>, an aperture in Spring <NUM>, and threadably engages with T-nut <NUM>; thereby securing all components together. Spring <NUM> has Ribs <NUM> that pass-through Rib Apertures <NUM> in the Top Clamp <NUM>. The interference of Ribs <NUM> and Rib Apertures <NUM> in the X and Y direction hold the Spring <NUM> and Top Clamp <NUM> in substantially the same rotational orientation around the fastener <NUM> if either or both the Spring <NUM> or Top Clamp <NUM> are rotated around the fastener <NUM>. The Ribs <NUM> and Rib Apertures <NUM> may not interfere in the Z direction so as to allow the Top Clamp <NUM> to compress the Spring <NUM> and move in the negative Z direction toward the T-nut <NUM> while the Spring <NUM> remains in substantially the same position along the Z axis. Spring <NUM> may have an Angled Protrusion <NUM>. The Angled Protrusion <NUM> may be symmetric along the central Y-plane of the Spring <NUM>, or it may be asymmetric. The Angled Protrusion <NUM> may have a flat angular surface as shown, or a curved surface. Top Clamp <NUM>, fastener <NUM>, and T-nut <NUM> may be constructed of an aluminum alloy, stainless steel alloy, carbon steel alloy, or another material with suitable strength properties. Spring <NUM> may be constructed using a polymer, with ultraviolet (UV) resistance and fire resistant properties.

<FIG> depicts a backside isometric view of Clamp <NUM>. In this example embodiment, the Top Clamp <NUM> extends down in the negative Z direction and is outside of the Spring <NUM>. Spring <NUM> may have one or more Spring Flanges <NUM> that engage with the T-nut <NUM> such that when the Spring <NUM> is rotated about the main axis of the fastener <NUM>, the T-nut <NUM> rotates substantially the same amount. In this example embodiment, one Spring Flange <NUM> is shown to protrude down and rests substantially coincident with a side of the T-nut. T-nut <NUM> may have one or more T-nut Flanges <NUM> that protrude upward at a determined angle. The T-nut Flanges <NUM> may be similarly shaped and angled on the opposing edges of the T-nut <NUM>. The T-nut <NUM> may have one of more Stop Flanges <NUM> that protrude upward in the positive Z direction. The T-nut <NUM> may have one or more ridges along the top surface near the T-nut Flanges <NUM> that can pierce a coating on a Rail <NUM>, such as anodization or paint, such that the T-nut <NUM> electrically bonds with the Rail <NUM>.

<FIG> depicts an underside isometric view of Clamp <NUM>. In this example, the T-nut has a Cone Embossment <NUM> formed into the T-nut <NUM> that provides additional threads in the T-nut <NUM> for the fastener <NUM> to threadably engage.

<FIG> depicts an isometric view of the Clamp <NUM> positioned over a representative section of Rail <NUM>. In this first step representing the installation of Clamp <NUM> into Rail <NUM>, the Clamp <NUM> is oriented with the long side of T-nut <NUM> substantially parallel with the length of the Rail <NUM>.

<FIG> depicts a second step of the installation of the Clamp <NUM> into the Rail <NUM>. In this example embodiment, the Clamp <NUM> has been partially inserted into the Rail Channel <NUM>. In this example, the Clamp <NUM> has not been rotated around the primary axis of the fastener <NUM>. The T-nut is positioned below the Rail Prongs <NUM> of the Rail <NUM>.

<FIG> depicts a third step of the installation of Clamp <NUM> into the Rail <NUM>. In this example next step, the Clamp <NUM> is rotated substantially around the primary Z axis of the fastener <NUM>. The T-nut rotates below the Rail Prongs <NUM>, and the Angled Protrusion <NUM> engages with the top edges of the Rail <NUM>, as shown in position <NUM>. As the Angled Protrusion <NUM> is engaged against the top of the Rail <NUM>, the Spring <NUM> compresses the Top Clamp <NUM> upward, thereby forcing up the T-nut <NUM> to engage with the Rail Prongs <NUM>.

<FIG> depicts a final fourth step in the installation of Clamp <NUM>. In this example next step, the Clamp <NUM> has been rotated substantially <NUM> degrees relative to its initial position. The Angled Protrusion <NUM> is fully engaged with the top edge or the Rail <NUM>. Stop Flanges <NUM> may interfere with the inside edge of the Rail <NUM> as shown in position <NUM> to prevent the Clamp <NUM> from rotating further.

<FIG> depict an end view of the same installation process as described and shown in <FIG>. <FIG> depicts an end view of <FIG> where the Clamp <NUM> is partially inserted into the open channel of Rail <NUM>. The T-nut <NUM> is positioned slightly below the lower points of the Rail Prongs <NUM>. In this example step of the installation, the long side of the Clamp <NUM> is parallel with the long edge of the Rail <NUM> in either the X or Y directions.

<FIG> depicts an end view of <FIG>. In this example next step, the Clamp <NUM> is rotated substantially around the primary Z axis of the fastener <NUM>. The T-nut rotates below the Rail Prongs <NUM>, and the Angled Protrusion <NUM> engages with the top edges of the Rail <NUM>, as shown in position <NUM>. As the Angled Protrusion <NUM> is engaged against the top of the Rail <NUM>, the Spring <NUM> compresses the Top Clamp <NUM> upward, thereby forcing up the T-nut <NUM> to engage with the Rail Prongs <NUM>.

<FIG> depicts an end view of the step between <FIG> and <FIG> wherein the Clamp <NUM> has rotated substantially <NUM> degrees from its original position and the Spring <NUM> is engaged with the top edges of the Rail <NUM>, but the Spring <NUM> is still compressed down such that the T-nut is not yet engaged with the Rail <NUM> at the Rail Prongs <NUM>. In this example embodiment, it is shown how the inside top edges of the Rail <NUM> are chamfered to a similar angle as the Angled Protrusion in order to coincide. A representative dimension of a Solar Module <NUM> is shown being positioned between the Top Clamp <NUM> and the top edge of the Rail <NUM>.

<FIG> depicts an end view of <FIG>. In this example next step, the Clamp <NUM> has been rotated substantially <NUM> degrees relative to its initial position. The Angled Protrusion <NUM> is fully engaged with the top edge or the Rail <NUM>. Stop Flanges <NUM> may interfere with the inside edge of the Rail <NUM> as shown in position <NUM> to prevent the Clamp <NUM> from rotating further. The T-nut Flanges <NUM> engage with the Rail Prongs <NUM> to prevent the T-nut <NUM> from rotating loose after installation, and to prevent the top edges of the Rail <NUM> from buckling outward upon being loaded in the Z direction. A representative dimension of a Solar Module <NUM> is shown being clamped between the Top Clamp <NUM> and the top edge of the Rail <NUM> upon the fastener <NUM> being threadably engaged with the T-nut <NUM>.

<FIG> show a first alternative example. <FIG> depicts an isometric view of the Channel Clamp <NUM>. The Channel Clamp <NUM> is an assembly of a Top Clamp <NUM>, a Spring <NUM>, a Channel Nut <NUM>, and a fastener <NUM>. The Channel Clamp <NUM> is oriented in the X, Y, and Z cartesian coordinate planes <NUM>. The fastener <NUM> extends through one or more apertures in the Top Clamp <NUM>, an aperture in Spring <NUM>, and threadably engages with Channel Nut <NUM>; thereby securing all components together. Spring <NUM> has Ribs <NUM> that pass-through Rib Apertures <NUM> in the Top Clamp <NUM>. The interference of Ribs <NUM> and Rib Apertures <NUM> in the X and Y direction hold the Spring <NUM> and Top Clamp <NUM> in substantially the same rotational orientation around the fastener <NUM> if either or both the Spring <NUM> or Top Clamp <NUM> are rotated around the fastener <NUM>. The Ribs <NUM> and Rib Apertures <NUM> may not interfere in the Z direction so as to allow the Top Clamp <NUM> to compress the Spring <NUM> and move in the negative Z direction toward the Channel Nut <NUM> while the Spring <NUM> remains in substantially the same position along the Z axis. Spring <NUM> may have an Angled Protrusion <NUM>. The Angled Protrusion <NUM> may be symmetric along the central Y-plane of the Spring <NUM>, or it may be asymmetric. The Angled Protrusion <NUM> may have a flat angular surface as shown, or a curved surface.

<FIG> depicts a backside isometric view of Channel Clamp <NUM>. Channel Nut <NUM> may have one or more Nut Flanges <NUM> with one or more Nut Prongs <NUM> on the outer corners of the Nut Flanges <NUM>. In this example embodiment, the Nut Prongs <NUM> are shaped to substantially contour Rail Prongs <NUM>. The top faces of Nut Prongs <NUM> may be at an angle relative to the X-Y plane such that one contoured edge is in a higher position along the Z axis relative to the other top edge of the contour. The top edge will present a sharp engagement with the Rail Prongs <NUM> in order to pierce a coating of the Rail <NUM>, such as anodization or paint, in order to provide an electrical bonding path between the Channel Nut <NUM> and the Rail <NUM>. Channel Nut <NUM> may be constructed of an aluminum alloy, stainless steel alloy, carbon steel alloy, or another material with suitable strength properties.

<FIG> depicts an underside isometric view of Channel Clamp <NUM>. In this example, the Channel Nut <NUM> has a Cone Embossment <NUM> formed into the Channel Nut <NUM> that provides additional threads in the Channel Nut <NUM> for the fastener <NUM> to threadably engage.

<FIG> depict the end view of the installation steps for the Channel Clamp <NUM> into a Rail <NUM>. <FIG> depicts the Channel Clamp <NUM> positioned over the Rail Channel <NUM> of the Rail <NUM>. <FIG> depicts the Channel Clamp <NUM> angled to allow the Channel Nut <NUM> to fit through the top edges of the Rail <NUM> and into the Rail Channel <NUM>. <FIG> depicts the Channel Clamp <NUM> lowered into the Rail Channel <NUM> such that all the Nut Prongs <NUM> are below the bottom surface of the Rail Prongs <NUM>. In this example embodiment, the Channel Clamp <NUM> has been angled back towards a vertical position slightly.

<FIG> depicts the Channel Clamp <NUM> angled back to a vertical position, and elevated upwards such that the Nut Prongs <NUM> engage with the Rail Prongs <NUM>. <FIG> depicts the Top Clamp <NUM> and Spring <NUM> rotating about the primary axis of the fastener <NUM> whilst the Channel Nut <NUM> remains substantially stationary. As the Spring <NUM> is rotated about the primary axis of the fastener <NUM>, the Angle Protrusion <NUM> engages with the top edges of the Rail <NUM> at position <NUM>.

<FIG> depicts a final position where the Top Clamp <NUM> and Spring <NUM> have rotated substantially <NUM> degrees relative to the position in <FIG>. The Spring <NUM> is now fully engaged with the top edge of the Rail <NUM> at position <NUM>. A representative dimension of a Solar Module <NUM> is shown being clamped between the Top Clamp <NUM> and the top edge of the Rail <NUM> upon the fastener <NUM> being threadably engaged with the Channel Nut <NUM>.

<FIG> depict <FIG> in an isometric view. <FIG> depicts <FIG> where the Channel Clamp <NUM> is position over the Rail <NUM>. <FIG> depicts the <FIG> after the Channel Clamp <NUM> has been positioned inside the Rail <NUM>, and the Top Clamp and Spring <NUM> are partially rotated about the primary axis of the fastener <NUM>. In this position, the Angled Protrusion <NUM> of Spring <NUM> may have begun to engage with the top inside edges of Rail <NUM>. <FIG> depicts an isometric view of <FIG> representing a final position of the Top Clamp <NUM> and Spring <NUM>. The Angled Protrusion <NUM> may be shaped such that when fully engaged with a chamfer on the top inside edges of the Rail <NUM>, the Top Clamp <NUM> and Spring <NUM> are held into a position substantially perpendicular to the length of the Rail <NUM>.

<FIG> show examples of a second alternative embodiment, according to the present invention. <FIG> illustrates an isometric view of the twist-lock clamp <NUM>. Twist-lock clamp <NUM> is an assembly of a Top Clamp <NUM>, a Spring <NUM>, a Bonding Clip <NUM>, a T-nut <NUM>, and a fastener <NUM>. The fastener <NUM> extends through one or more apertures in the Top Clamp <NUM>, an aperture in Spring <NUM>, an aperture in Bonding Clip <NUM> and threadably engages with T-nut <NUM>; thereby securing all components together. Spring <NUM> has Ribs <NUM> that pass-through Rib Apertures <NUM> in the Top Clamp <NUM>. The interference of Ribs <NUM> and Rib Apertures <NUM> in the X and Y direction hold the Spring <NUM> and Top Clamp <NUM> in substantially the same rotational orientation around the fastener <NUM> if either or both the Spring <NUM> or Top Clamp <NUM> are rotated around the fastener <NUM>. The Ribs <NUM> and Rib Apertures <NUM> may not interfere in the Z direction so as to allow the Top Clamp <NUM> to compress the Spring <NUM> and move in the negative Z direction toward the T-nut <NUM> while the Spring <NUM> remains in substantially the same position along the Z axis. Spring <NUM> may have an Angled Protrusion <NUM>. The Angled Protrusion <NUM> may be symmetric along the central Y-plane of the Spring <NUM>, or it may be asymmetric. The Angled Protrusion <NUM> may have a flat angular surface as shown, or a curved surface.

T-nut <NUM> may be constructed of an aluminum alloy, stainless steel alloy, carbon steel alloy, or another material with suitable strength properties. T-nut <NUM> has a Cone Embossment <NUM> formed into the T-nut <NUM> that provides additional threads for the fastener <NUM> to threadably engage.

In addition to the central threaded aperture in Cone Embossment <NUM>, T-nut <NUM> also has laterally offset apertures <NUM>. These laterally offset apertures <NUM> cooperate with nut snaps <NUM> in Spring <NUM>. The cooperation of nut snaps <NUM> and laterally offset apertures <NUM> hold the Spring <NUM> and T-nut <NUM> in substantially the same rotational orientation around the fastener <NUM>. That cooperation also holds T-nut <NUM> and Spring <NUM> in relative position if fastener <NUM> and T-nut <NUM> become disconnected.

T-nut <NUM> has offset raised contact points <NUM>, which present a sharp engagement with Rail Prongs <NUM> in order to pierce a coating of the Rail <NUM>, such as anodization or paint, in order to provide an electrical bonding path between T-nut <NUM> and Rail <NUM>.

T-nut <NUM> has a top planar surface with a wide dimension <NUM>, and a narrow dimension <NUM>. The wide dimension <NUM> of T-nut <NUM> is greater than the width between Rail Prongs <NUM> of Rail Channel <NUM>. The narrow dimension <NUM> of T-nut <NUM> is less than the width between Rail Prongs <NUM> of Rail Channel <NUM>. The difference in dimensions <NUM> and <NUM> allow T-nut <NUM> to be inserted between Rail Prongs <NUM> of Rail Channel <NUM>, and then when T-nut <NUM> is rotated <NUM> degrees, the T-nut <NUM> is captured in Rail Channel <NUM> by Rail Prongs <NUM>. Nut Flanges <NUM> of T-nut <NUM> are also planar, and generally rectangular, having a dimension <NUM> that is less than wide dimension <NUM>. Nut Flanges <NUM> are also offset so that one edge of Nut Flange <NUM> is generally aligned with a narrow edge of the top planar surface. This offset of Nut Flanges <NUM> allows T-nut <NUM> to rotate about <NUM> degrees when inserted in Rail Channel <NUM>. Efforts to rotate T-nut <NUM> substantially beyond <NUM> degrees are prevented when the Nut Flanges <NUM> interfere with the walls of Rail Channel <NUM>.

Bonding Clip <NUM> has an aperture <NUM>, a first flange <NUM>, a second flange <NUM>, and a pair of third flanges <NUM>. Aperture <NUM> allows fastener <NUM> to pass through. First flange <NUM> can pass through aperture <NUM> in Top Clamp <NUM>. First and second flanges <NUM> and <NUM> have raised contact points <NUM>. The raised contact points <NUM> are on both sides of second flange <NUM>. On first flange <NUM>, the raised contact points are also on both sides, although they may be different configurations. Bonding Clip <NUM> may be constructed of a stainless steel alloy, carbon steel alloy, or another material with suitable strength properties. In general the strength properties of Bonding Clip <NUM> are equal to or greater than the strength properties of Top Clamp <NUM>. As illustrated in <FIG>, Bonding Clip <NUM> has labeling to indicate which side of the Clamp faces an end panel. <FIG> also illustrates two possible variations on the configuration of Bonding Clip <NUM>.

As illustrated in <FIG>, the under surface of fastener <NUM> has raised rings <NUM> in order to pierce a coating of top clamp <NUM>, such as anodization or paint, in order to provide an electrical bonding path between fastener <NUM> and top clamp <NUM>.

<FIG> illustrates lettering on a bonding clip.

<FIG> show examples of a third alternative embodiment of the present invention. <FIG> illustrates a left isometric view of the twist-lock clamp <NUM>, and <FIG> illustrates a right isometric view of the twist-lock clamp <NUM>. Many of the features illustrated and described above, are the same in this third alternative embodiment. In one difference between the earlier described embodiments, and the third alternative embodiment, the Bonding Clip <NUM> is replaced by one or more Bond Pins <NUM> on the lower surface of Top Clamp <NUM>. In this third alternative embodiment, Bond Pins <NUM> are inserted into the lower surface of Top Clamp <NUM>, such as by drilling, screwing or pressing. The Bond Pins <NUM> are typically stainless steel or another material that is harder than the solar module frame that is contacted by the Bond Pins when the Clamp is installed.

<FIG> illustrate isometric views of the second alternative embodiment as the twist-lock clamp <NUM> is installed in a rail. In <FIG>, the twist-lock clamp <NUM> is partially inserted in the Rail Channel <NUM>. In <FIG>, the T-nut is pressed down below Rail Prongs <NUM>, and the twist-lock clamp <NUM> is partially rotated. In <FIG>, the twist-lock clamp <NUM> is rotated into final position, and the T-nut is still pressed down below the Rail Prongs <NUM>. In <FIG>, the twist-lock clamp <NUM> is rotated into final position, and the T-nut is raised and engaged with Rail Prongs <NUM>.

<FIG> illustrate end views of the second alternative embodiment as the twist-lock clamp <NUM> is installed in a rail. In <FIG>, the twist-lock clamp <NUM> is partially inserted in the Rail Channel <NUM>. In <FIG>, the T-nut is pressed down below Rail Prongs <NUM>, and the twist-lock clamp <NUM> is partially rotated. In <FIG>, the twist-lock clamp <NUM> is rotated into final position, and the T-nut is still pressed down below the Rail Prongs <NUM>. In <FIG>, the twist-lock clamp <NUM> is rotated into final position, and the T-nut is raised and engaged with Rail Prongs <NUM>.

Claim 1:
A twist-lock clamp (<NUM>) for attaching a solar module to a rail, comprising:
a threaded fastener (<NUM>);
a top clamp (<NUM>) having:
a first planar member;
a first aperture in the first planar member, the first aperture to accept the threaded fastener in an assembled configuration; and
a second planar member orthogonal to the first planar member and connected to the first planar member adjacent to the first aperture;
a spring (<NUM>) having:
a second aperture to accept the threaded fastener in the assembled configuration; and
a first planar surface configured to engage with a second planar surface on the rail in a locked configuration;
a threaded t-nut (<NUM>) to engage with the threaded fastener placing the spring in compression between the top clamp and the threaded t-nut in the assembled configuration; and
a bonding clip (<NUM>) having a cutout and a plurality of raised contact points, wherein the cutout allows the threaded fastener to pass through in the assembled configuration.