Patent ID: 12212280

DETAILED DESCRIPTION

Stacks of solar panels may be shipped on a pallet with spacers between individual solar panels to prevent damage. The spacers, such as side spacer clips and corner spacer clips, may be placed on each solar panel during packaging and removed and discarded prior to installation. Positive and negative wire leads are often coiled, zip-tied, and/or taped to the back of the solar panel. Other packaging materials, such as cardboard and plastic wrap, may be additionally used to protect the solar panel during shipping.

Prior to installation, the installer may remove and discard the packaging materials, including the various spacer clips. Wire management clips may then be added to the solar panel to route the wire leads prior to installation. The wire management clips may be used to, for example, maintain the wires elevated above a roof of a structure or other mounting surfaces.

This disclosure includes several embodiments and variations of multifunction solar panel spacer-wire clips. The described multifunction solar panel spacer-wire clips are multifunctional in that they may be used during shipping as spacers between stacked solar panels and remain in place (i.e., are not discarded), and may also be used for wire management during installation (e.g., to route and manage power wires, data cables, or the like). The multifunction solar panel spacer-wire clips may be referred to as dual-purpose solar panel clips, multifunction module spacer-wire clips, or all-in-one module spacer-wire clips, where the term “module” refers to an assembly (e.g., a two-dimensional array) of solar cells wired in series and/or parallel and packaged as a single panel with positive and negative wire leads that are externally accessible. The term “spacer-wire clip” is used herein for shorthand to describe many of the variously described embodiments.

As described herein, many solar panels (or “modules”) include a frame around the perimeter of the array of solar cells with a flange that can be used for mounting the solar panel to the roof or other mounting surface. The embodiments of the disclosure can be understood with reference to the drawings. It will be readily understood that the components of the disclosed embodiments, as generally described and illustrated in the figures herein, could be arranged and designed in a wide variety of different configurations and dimensions. Thus, the following detailed description of the embodiments of the systems and methods of the disclosure is not intended to limit the scope of the disclosure, as claimed, but is merely representative of possible embodiments of the disclosure. In addition, the steps of a method, such as the steps for clip installation, do not necessarily need to be executed in any specific order, or even sequentially, nor do the steps need to be executed only once, unless otherwise specified.

For example, the specific dimensions of a given spacer-wire clip may be adjusted to increase the friction fit on a frame of a given solar panel. Additionally, the dimensions of a spacer-wire clip may be modified to accommodate frames having different lateral heights and/or flanges with different widths. Moreover, the thickness of a spacer-wire clip may be adjusted to increase or decrease the spacing between solar panels stacked for shipping.

In some cases, well-known features, structures, or operations are not shown or described in detail. Furthermore, the described features, structures, or operations may be combined in any suitable manner in one or more embodiments. It will also be readily understood that the components of the embodiments, as generally described and illustrated in the figures herein, could be arranged and designed in a wide variety of different configurations. For example, throughout this specification, any reference to “one embodiment,” “an embodiment,” or “the embodiment” means that a particular feature, structure, or characteristic described in connection with that embodiment is included in at least one embodiment. Thus, the quoted phrases, or variations thereof, as recited throughout this specification are not necessarily all referring to the same embodiment.

It is recognized that a wide variety of materials and manufacturing techniques may be used to fabricate the various embodiments of spacer-wire clips described herein. In some embodiments, the spacer-wire clips may be a single monolithic material. In additional embodiments, multiple materials may be utilized. For example, a first material may be used to provide sufficient rigidity and strength for the spacer-wire clip to function for wire routing and management for many years, while another material may be used as a coating, outer layer, and/or in specific contact locations to provide cushioning, impact absorption, abrasion resistance, and/or otherwise protect stacked solar panels during shipping. In some embodiments, the spacer-wire clips may be manufactured with a metal core or metal layer. In other embodiments, the spacer-wire clips are manufactured using one or more polymers, plastics, and/or rubbers.

Examples of suitable materials to fabricate the various embodiments of spacer-wire clips described herein include but are not limited to, ABS, TPE, TPU, PLA, HIPS, PETG, carbon-fiber-infused PLA or ABS, ASA, polycarbonate, polypropylene, polyethylene ether (e.g., Sabic Noryl SE1X), or the like. Various metals and metal alloys may be utilized in some embodiments. The various embodiments of spacer-wire clips may be three-dimensionally printed, thermoformed, die cut, solvent welded, injection molded, rotationally molded, extrusion blow molded, injection blow molded, vacuum cast, and/or otherwise fabricated using fabrication techniques known to be useful for fabricating plastic, rubber, and/or metal components.

FIG.1is an image of a plurality of solar panels100on a pallet110for shipping, according to one embodiment. As illustrated, the solar panels100are spaced from one another using white spacers112that are used for shipping and then discarded. Negative and positive wires114of the solar panel100are coiled, bound with a zip tie, and taped to the back of the panel. Each of the solar panels100may be further wrapped in cardboard or plastic for additional protection. As described herein, much of the packing and shipping materials must be removed and discarded (e.g., wasted) prior to the installation of the solar panels100.

FIG.2Ais an image of an example corner spacer clip200that is used to space solar panels from one another during shipping. The spacer clip200is disposable and serves no purpose other than to protect and space the solar panels from one another during shipping. As described herein, the spacer clips200are removed from the solar panels and discarded prior to installation.

FIG.2Bis an image of the corner spacer clip200installed on a flange210of a solar panel212.

FIGS.3A,3B, and3Care images of disposable side clips300used to protect and separate solar panels310during shipping, according to one embodiment. Again, the illustrated spacer clips300are examples of disposable spacer clips used during shipping. The illustrated spacer clips300are removed and discarded prior to the installation of the solar panels310.

FIG.3Dillustrates an example of a metal wire clip320that is installed on the solar panel310after shipping during installation for wire management, according to one embodiment. As is readily apparent, the metal wire clip320cannot function as a spacer for impact protection during shipping. Accordingly, the metal wire clip320is installed after shipping (e.g., after the removal and disposal of spacer clips, such as the spacer clips300and/or the corner spacer clips200illustrated inFIGS.2A-3C).

FIG.4Aillustrates a solar panel410with positive and negative wires414coiled and taped to the back of the solar panel410for shipping, according to one embodiment. The illustrated embodiment shows the disposable spacer clips removed from the solar panel410prior to installation. Care must be taken to ensure that the wires414are not damaged by the installer when trying to remove (e.g., cut) the tape and/or zip ties that secure the wires414during transportation and shipping.

FIG.4Billustrates metal wire clips420added to the sides of the solar panel410for connection to a panel-mounted microinverter or power optimizer device430prior to installation, according to one embodiment. As illustrated, the negative and positive wires414are routed along a flange495of the solar panel410using metal wire clips420that are added to the solar panel410to route the wires414for connection to the leads on the microinverter or power optimizer device430that is also secured to the flange495of the solar panel410. Additional metal wire clips420are shown added to the top corner flanges of the solar panel410to route the external connections of the microinverter or power optimizer device430.

FIG.4Cillustrates a cross-sectional view of a portion of a frame490and flange495of the solar panel410illustrated inFIGS.4A and4B, according to one embodiment. As an example, the frame490may have a height of approximately 30 millimeters. An upper cavity401may secure glass, solar cells, wires, and backing of the solar panel410(illustrated in dashed lines). A lower cavity405is formed between the inner surface of the flange495and the backing of the solar panel410. The external surface of the flange495may be mounted to the roof or other mounting surface during installation. The wire clips420inFIG.4B(e.g., the metal wire clip320inFIG.3D) are secured to the flange495during the installation of the solar panel410, after disposable spacer clips (e.g., the spacer clips300and/or the corner spacer clips200illustrated inFIGS.2A-3C) used for protection during shipping have been removed.

In some embodiments, metal wire clips may be added to the solar panel flanges to route the negative and positive wires of the solar panel directly for external connection without the use of the microinverter or power optimizer device.

Existing shipping and installation approaches include removing and discarding the disposable spacer clips (e.g., the spacer clips300and/or the corner spacer clips200illustrated inFIGS.2A-3C), uncoiling and removing the zip ties from the coiled wires (seeFIG.4), adding single-purpose metal wire clips to the flanges to route the solar panel wires, and routing the solar panel wires through the newly added metal wire clips. This existing shipping and installation approach takes a significant amount of time, can easily result in damage to the wires (e.g., when cutting the zip ties binding the wires), and results in a significant amount of wasted material (e.g., the discarded spacer clips used only for shipping).

As described in greater detail below, multifunction spacer-wire clips according to embodiments of the present disclosure may be installed prior to shipping to protect the solar panels during shipping and may then be used during installation to route and manage the wires. The multifunction spacer-wire clips can additionally be used to secure the wires during shipping as well to obviate and/or reduce the need for zip ties and tape. Accordingly, the spacer-wire clips described herein may provide the same or improved shipping protection as offered by the spacer clips described above, but do not need to be removed prior to installation. In fact, they can be used to secure the wires during shipping, during installation, and for many years thereafter.

FIG.5Aillustrates a perspective view of a multifunction spacer-wire clip500, according to one embodiment. As illustrated, the example spacer-wire clip500includes a main body portion510, having an upper surface511, and an opposing external surface513. The upper surface511of the main body portion510may contact an external surface of a flange of a solar panel during installation. The main body portion510may be sized and positioned to space an external surface of the flange of the solar panel from an adjacent solar panel and prevent direct contact between the solar panel and the adjacent solar panel when the solar panel is positioned adjacent to the other solar panel in a stacked arrangement.

A flange overhang portion530may define a flange cavity535sized and configured to receive a portion of a flange of a solar panel. The flange cavity535may be defined between the upper surface511of the main body portion510and the flange overhang portion530. Accordingly, an inner edge of the flange of a solar panel may be inserted within the flange cavity535such that the flange overhang portion530may be secured against the inner surface of the flange of the solar panel and the upper surface511of the main body portion510may be secured against the external surface of the flange of the solar panel. The edge of the flange of the solar panel may contact the inner surface of a connecting wall532connecting the flange overhang portion530to the main body portion510of the spacer-wire clip500. In the illustrated example, the connecting wall532is vertical and forms 90-degree angles relative to the main body portion510and the flange overhang portion530. In additional embodiments, the connecting wall532may be rounded or at different acute or obtuse angles relative to the main body portion510and the flange overhang portion530.

A frame arm portion520may extend perpendicular to the main body portion510at an end of the main body portion510. The frame arm portion520comprises a surface sized and located to be positioned against an outer perimeter of the frame of the solar panel and prevent the portion of the flange from removal from the flange cavity535when the frame arm portion520is positioned against the outer perimeter of the frame. Accordingly, the upper inside surface521of the frame arm portion520may contact the outer perimeter of a frame of a solar panel during installation, as described and illustrated in greater detail below.

The frame arm portion520may comprise a first portion526extending perpendicular to the main body portion510at a first end of the main body portion510, the first portion526positioned to be adjacent to a solar panel when the spacer-wire clip500is installed on the solar panel. The frame arm portion520may further comprise a second portion528extending perpendicular to the main body portion510at the first end of the main body portion510and in a direction opposite the first portion526, the second portion528positioned to be adjacent an edge of an adjacent solar panel when the spacer-wire clip500is installed on a solar panel and the solar panel is positioned adjacent to another solar panel in a stacked arrangement.

The main body portion510may continue past the connecting wall532in the same plane (as illustrated) or at an angle relative to a body extension512connected to a wire retainer540. The wire retainer540may be positioned above and spaced apart from the body extension512to form a wire cavity541. Accordingly, the wire retainer540extending from the main body portion510may be sized and configured to selectively retain at least one wire within at least one wire cavity541. As shown, the wire cavity541may be configured to receive and retain wires of the solar panel and/or other data or power cables routed to, from, or past the solar panel. Additionally, the wire retainer540may include protrusions and/or intrusions542to receive and retain wires more effectively and prevent movement (e.g., lateral movement) of wires within the wire cavity541. The illustrated embodiment shows two intrusions542to secure two separate wires spaced slightly from one another (or touching if the wires are thick enough) within the wire cavity541.

The wire retainer540may be positioned on the main body portion510of the spacer-wire clip500such that an opening for inserting a wire into the wire cavity541of the wire retainer540is positioned at a location between the main body portion510of the spacer-wire clip500and the backing of a solar panel when the spacer-wire clip500is positioned on the solar panel.

It is appreciated that any number of frictional features, protrusions, intrusions, or other features may be present on the inner surface of the wire retainer540to secure any number of wires therein. In the illustrated embodiment, a curved wall543connects the wire retainer540to the body extension512. The arcuate surface of a curved wall543may be specifically selected to accommodate a wire having a known diameter or wires having specific diameter ranges. Accordingly, the wire retainer540may comprise an arcuate surface with an inner radius substantially matching an outer radius of a wire of a solar panel. In additional embodiments, the curved wall543may be modified to be a straight wall at a 90-degree angle (or another angle) relative to the body extension512and the wire retainer540.

Accordingly, the wire retainer540may be configured to open to allow the insertion of at least one wire into the wire cavity541in response to applying a force to the wire retainer540with the at least one wire. The wire retainer540may be configured to resiliently return to a closed position after a wire is positioned within the wire cavity541. Additionally, one or more protrusion located at an opening into the wire cavity541may be positioned to provide resistance to the removal of a wire from the at least one wire cavity541after the wire is positioned therein.

FIG.5Billustrates another perspective view of the spacer-wire clip500. The thickness of the main body portion510may be selected to provide a target spacing between solar panels stacked upon one another during shipping. Furthermore, the spacer-wire clip500may be manufactured with a shock absorptive polymer, plastic, and/or rubber to absorb shocks during shipping and maintain spacing to prevent scratching or other damage. In some embodiments, the external surface513of the spacer-wire clip500is in contact with adjacent solar panels during shipping (e.g., a top edge of a frame of an adjacent solar panel) and may be made from a polymer, plastic, and/or rubber selected to have target non-abrasive and/or impact absorption properties. In other embodiments, the external surface513may include a polymer, plastic, and/or rubber coating or layer selected to have target non-abrasive and/or impact absorption properties that is a different material than the rest of the spacer-wire clip500. A lower inside surface522of the frame arm portion520may likewise be made from, include a coating, or include a layer of a polymer, plastic, and/or rubber selected to have target non-abrasive and/or impact absorption properties.

In some embodiments, the entire spacer-wire clip500may be a monolithic structure manufactured from a single material selected to retain wires within the wire cavity541for many years, remain secured to the flange and frame of the solar panel for many years, and provide sufficient impact and/or abrasion protection during shipping. The spacer-wire clip500may be manufactured using, for example, and without limitation, nylon, polyethylene, a composite nylon polyamide with polyethylene fibers, copolymer acetal, acetal homopolymer, polyamide, rubber-coated nylon, acrylate, or the like. In some embodiments, a removable or permanent rubber or foam layer may be applied to the external surface513of the main body portion510to increase the impact absorption properties of the spacer-wire clip500.

FIG.5Cillustrates a side view of the multifunction spacer-wire clip500with example dimensions. The example dimensions are specifically selected based on the thickness and dimensions of the frame and flange of a particular solar panel. The exact dimensions, spacings, and thicknesses can be adapted and adjusted to accommodate solar panel frames and flanges of various shapes and sizes. Similarly, the dimensions, spacings, and thicknesses can be adapted and adjusted to accommodate a different number of wires and/or different thicknesses of wires.

In some embodiments, the flange of the solar panel may have predrilled holes or indents. The spacer-wire clip500may, as illustrated, include a protrusion550within the flange cavity535. The protrusion550may extend from main body portion510and be sized and positioned to mate with an aperture in the flange of a solar panel to align the spacer-wire clip500with a location on the solar panel and maintain the position of the spacer-wire clip500at the location on the solar panel.

The protrusion550may be sized to enter or partially enter the predrilled hole or indent in the flange of a solar panel. The protrusion550may serve to align the spacer-wire clip500in specific locations on the flange of the solar panel and prevent the spacer-wire clip500from sliding laterally along the flange. In some embodiments, the solar panel may, for example, have holes drilled at predetermined intervals along the flange that can be used to position spacer-wire clips500in target locations along the flange prior to shipping. The spacer-wire clips500may be retained in the same locations during installation and use of the solar panel or moved to new locations along the flange (e.g., corresponding to alternative predrilled holes in the flange).

FIG.5Dillustrates a top view of the multifunction spacer-wire clip500with example dimensions. Again, it is appreciated that different widths between approximately 10 millimeters and 80 millimeters may be utilized to provide different amounts of spacer protection during shipping and/or wire retention strengths during installation and use of the solar panel. The length of the spacer-wire clip is illustrated as an example 67 millimeters but may be modified depending on the thickness of the frame of the solar panel, the width of the flange of the solar panel, the number of wires to be retained within the wire cavity, and/or the diameter(s) of the wire(s) to be retained within the wire cavity. Additionally, as shown, the spacer-wire clip500may have a substantially uniform width (e.g., about 40 mm) along the entire length of the spacer-wire clip500.

FIG.5Eillustrates a perspective view of the multifunction spacer-wire clip500next to a flange595of a solar panel. In the illustrated example, a frame590of the solar panel is at a 90-degree angle relative to the flange595and the flange595includes a hole. The spacer-wire clip500may, in some embodiments, include a protrusion to interact with and partially enter the hole to retain the spacer-wire clip500on the flange595and prevent or limit lateral movement of the spacer-wire clip500along the flange595.

FIG.5Fillustrates another perspective view of the multifunction spacer-wire clip500flexing for placement on the flange595of the solar panel, according to one embodiment. As described herein, the spacer-wire clip500may be manufactured using one or more materials or composites of materials (homogenous or layered) that allow for the spacer-wire clip500to be deformably flexed during installation and resiliently return to its original shape for long-term retention on the flange595of the solar panel.

FIG.5Gillustrates another perspective view of the multifunction spacer-wire clip500being placed on the flange595of the solar panel, according to one embodiment. As illustrated, the edge of the flange595enters the flange cavity535, and the frame arm520is flexed downward to extend beyond the edge of the frame590.

FIG.5Hillustrates another perspective view of the multifunction spacer-wire clip500secured to the flange595of the solar panel, according to one embodiment. As illustrated, the flange595is positioned within the flange cavity535and the upper portion of the frame arm520is secured to the outer surface of the frame590. Again, in some embodiments, a protrusion within the flange cavity535may interact with the hole in the flange595.

FIG.6Aillustrates multifunction spacer-wire clips600(e.g., spacer-wire clips500,700,800,900,1000,1100,1200,1220,1240,1260,1280,1300, and/or1400) secured to a solar panel610during shipping, according to one embodiment. As illustrated, and in contrast to the images and illustrations ofFIGS.1-4A, the spacer-wire clips600are used to route the negative and positive lead wires614of the solar panel610during shipping, thereby avoiding the need to coil and zip tie the wires614. The ends of the wires614may be taped, as illustrated, to the back of the solar panel610. Alternatively, the ends of the wires614(e.g., with MC4 connectors) may be positioned more closely to the spacer-wire clips600to avoid the need for any tape. The configuration shown inFIG.6Amay be used to stack and ship the solar panels610, with the spacer-wire clips600serving the dual functions of spacing the solar panels610to avoid abrasion, providing impact absorption and solar panel separation, and securing the wires614during shipping.

FIG.6Billustrates the multifunction spacer-wire clips600used for cable routing during installation, according to one embodiment. As illustrated, the spacer-wire clips600used for shipping inFIG.6Aare now used for routing the wire leads to the newly installed microinverter or power optimizer630. Some of the additional spacer-wire clips600in the upper corners used for shipping protection inFIG.6Aare now used to route the external facing wires650of the microinverter or power optimizer630. In the example embodiment, the unused spacer-wire clips600in the bottom corners are removed prior to installation and use of the solar panel610since they were not needed for wire routing. However, in other embodiments, the unused spacer-wire clips600in the bottom corners may be left in place and simply not used for wire routing.

FIG.7illustrates an embodiment of a multifunction spacer-wire clip700with a dynamic wire retainer740and a single-direction frame arm720having a first portion726extending perpendicular to a main body portion710at a first end of the main body portion710, according to one embodiment. The dynamic wire retainer740may function to selectively secure one wire or multiple wires having different diameters by flexing upward relative to the underlying main body portion710and resiliently returning to substantially the same position and shape after a wire is inserted. The first portion726may be positioned to be adjacent to a solar panel when the spacer-wire clip700is installed on the solar panel, and the single-direction frame arm720may not include a second portion extending perpendicular to the main body portion710at the first end of the main body portion710and in a direction opposite the first portion726.

FIG.8illustrates an embodiment of a multifunction spacer-wire clip800with a single cable clip (e.g., wire retainer840to accommodate a single wire) and a shortened flange overhang portion830, according to one embodiment. The shortened flange overhang portion830may make for easier placement that requires less flexing of a main body portion810.

FIG.9illustrates an embodiment of a multifunction spacer-wire clip900with a dual-cable clip (e.g., wire retainer940to accommodate two wires) and a shortened flange overhang portion930, according to one embodiment.

FIG.10illustrates an embodiment of a multifunction spacer-wire clip1000with a dual-direction frame arm1020without an alignment protrusion, according to one embodiment. The upper portion1026of the dual-direction frame arm1020may extend around the frame of a solar panel on which the spacer-wire clip1000is mounted. The lower portion1028of the dual-direction frame arm1020may extend around the frame of an adjacent solar panel during shipping to maintain the solar panel stack alignment during shipping. In some embodiments, the lower portion1028of the dual-direction frame arm1020may be selectively removed (e.g., cut or flexibly broken off at an intentionally weakened joint) after shipping.

FIG.11illustrates an embodiment of a multifunction spacer-wire clip1100with a single-direction frame arm1120without an alignment protrusion, according to one embodiment. As previously described, some embodiments of the spacer-wire clip1100may ship with the single-direction frame arm1120. Such embodiments may not offer stack alignment functionality during shipping, but such functionality may not be necessary for some implementations. In other embodiments, the spacer-wire clip1100may be shipped with a lower portion of the frame arm1120in place to provide stack alignment functionality during shipping, as shown inFIG.10. The spacer-wire clip may then be transitioned to the embodiment shown inFIG.11by removing (e.g., by cutting or breaking) the lower portion of the frame arm1100after shipping for flush mounting the flange of the solar panel during installation and solar panel usage.

FIG.12Aillustrates a side view of a narrow multifunction spacer-wire clip1200, according to one embodiment. As illustrated, the dimensions of the spacer-wire clip1200inFIG.12Aare the same as those of spacer-wire clip500shown inFIG.5C.

FIG.12Billustrates a top view of the narrow multifunction spacer-wire clip1200. In contrast to the spacer-wire clip500ofFIG.5D, the narrow multifunction spacer-wire clip1200is only 20 millimeters wide, instead of 40 millimeters wide. Again, the exact dimensions may be adapted for a particular application and usage scenario.

FIG.12Cillustrates a top view of an additional multifunction spacer-wire clip1220with variable widths, according to one embodiment. As illustrated, a frame arm1221may have a relatively small width and reduced thickness to minimize its appearance on the outer perimeter of the frame of an installed solar panel. The width of a main body portion1222may be larger to provide an increased surface area for impact absorption between solar panels during shipping. The width of a flange overhang portion1223may remain a sufficient size to maintain the edge of the flange within a flange cavity.

The width of a wire retainer1224may be enlarged to secure a larger portion of inserted wires, while the width of a body extension1225underneath the wires may be a different width (illustrated as slightly wider) to facilitate insertion of the wires within a wire cavity between the wire retainer1224and the body extension1225. The portion of the body extension1225between the flange overhang portion1223and the wire cavity may be a different width as well, as illustrated.

FIG.12Dillustrates a side view of an additional multifunction spacer-wire clip1240with a wire retainer1241positioned above a flange overhang portion1242, according to one embodiment. As illustrated, a curved wall and the wire retainer1241extend from and are positioned above the flange overhang portion1242. In the illustrated embodiment, a wire cavity1243is formed between the upper surface of the flange overhang portion1242and the wire retainer1241. During installation, wires may be positioned within the wire cavity1243that is above the flange of the solar panel.

FIG.12Eillustrates a side view of an additional multifunction spacer-wire clip1260with a wire retainer1261inverted and extending from a flange overhang portion1262, according to one embodiment.

FIG.12Fillustrates a side view of an additional multifunction spacer-wire clip1280with a protrusion1281extending from a flange overhang portion1282, according to one embodiment. The protrusion1281may be sized and positioned to interact with (e.g., partially enter) a hole in the flange of a solar panel. The protrusion1281may facilitate placement and alignment of the spacer-wire clip1280and prevent the spacer-wire clip1280from sliding laterally along the flange of the solar panel. In some embodiments the protrusion1281may have a circular or oval shape with a diameter corresponding to that of the holes in the flange of a solar panel. For example, the circular (or oval) protrusion1281may have a diameter (or major and minor axes) between approximately 3 millimeters and 12 millimeters. The height of the protrusion1281may correspond to the thickness of the flange of the solar panel. For example, the protrusion1281may have a height between approximately 1 millimeter and 5 millimeters.

One purpose of describing the additional spacer-wire clips1220,1240,1260,1280illustrated inFIGS.12C,12D,12E, and12Fis to emphasize that the exact dimensions, widths, and thicknesses may be uniform, but are not necessarily uniform. Variations in the specific widths and thicknesses may increase strength, absorptive properties, wire retention capabilities, etc., while reductions in specific widths and thicknesses may increase visual appearance (minimize intrusiveness), facilitate easier wire insertion, facilitate easier flange/frame mounting, etc. Another purpose of providingFIGS.12C,12D,12E, and12Fis to illustrate that the wire retainer portion1224,1241,1261of the spacer-wire clips1220,1240,1260,1280may be moved, repositioned, resized, and/or inverted with respect to the rest of the spacer-wire clip1220,1240,1260,1280.

FIG.13Aillustrates an isometric view of a multifunction spacer-wire clip1300with wire cavity1341configured to accommodate a plurality of wires, according to an additional embodiment. As illustrated, the spacer-wire clip1300includes a main body portion1310, having an upper surface1311, and an opposing external surface1313(FIG.13B). The upper surface1311of the main body portion1310may contact an external surface of a flange of a solar panel during installation. The main body portion1310may be sized and positioned to space an external surface of the flange of the solar panel from an adjacent solar panel and prevent direct contact between the solar panel and the adjacent solar panel when the solar panel is positioned adjacent to the other solar panel in a stacked arrangement.

The spacer-wire clip1300may include a central part line1314from which surfaces of the spacer-wire clip1300may be tapered to facilitate the removal of the spacer-wire clip1300from a mold (e.g., an injection mold) during the manufacture of the spacer-wire clip1300. Additionally, edges of the spacer-wire clip1300may be rounded to aid in manufacturing (e.g., to ease in machining of a mold and/or to prevent short shots in an injection molding process) and/or to provide smooth edges to prevent scratching of solar panels by operators handling the spacer-wire clips1300.

A flange overhang portion1330may define a flange cavity1335sized and configured to receive a portion of a flange of a solar panel. The flange cavity1335may be defined between the upper surface1311of the main body portion1310and the flange overhang portion1330. Accordingly, an inner edge of the flange of a solar panel may be inserted within the flange cavity1335such that the flange overhang portion1330may be secured against the inner surface of the flange of the solar panel and the upper surface1311of the main body portion1310may be secured against the external surface of the flange of the solar panel. The edge of the flange of the solar panel may contact the inner surface of a connecting wall1332connecting the flange overhang portion1330to the main body portion1310of the spacer-wire clip1300.

A frame arm portion1320may extend perpendicular to the main body portion1310at an end of the main body portion1310, The frame arm portion1320comprises a surface sized and located to be positioned against an outer perimeter of the frame of the solar panel and prevent the portion of the flange from removal from the flange cavity1335when the frame arm portion1320is positioned against the outer perimeter of the frame. Accordingly, an upper inside surface1321of the frame arm portion1320may contact the outer perimeter of a frame of a solar panel during installation, as described and illustrated in greater detail below.

The frame arm portion1320may comprise a first portion1326extending perpendicular to the main body portion1310at a first end of the main body portion1310, the first portion1326positioned to be adjacent to a solar panel when the spacer-wire clip1300is installed on the solar panel. The frame arm portion1320may further comprise a second portion1328extending perpendicular to the main body portion1310at the first end of the main body portion1310and in a direction opposite the first portion1326, the second portion1328positioned to be adjacent an edge of an adjacent solar panel when the spacer-wire clip1300is installed on a solar panel and the solar panel is positioned adjacent to another solar panel in a stacked arrangement.

The main body portion1310may continue past the connecting wall1332in the same plane (as illustrated) or at an angle relative to a body extension1312connected to a wire retainer1340. The wire retainer1340may be positioned above and spaced apart from the body extension1312to form the relatively large wire cavity1341. Accordingly, the wire retainer1340extending from the main body portion1310may be sized and configured to selectively retain at least one wire within at least one wire cavity1341. As shown, the wire cavity1341may be configured to receive and retain a plurality of wires of the solar panel and/or other data or power cables routed to, from, or past the solar panel, that may be a variety of sizes in diameter.

The wire retainer1340may include a groove1344near an opening to the wire cavity1341. The groove1344may correspond to a protrusion1346extending from the main body portion1310at a location adjacent to the flange overhang1330. Additionally, an end1345of the wire retainer1340may be angled toward the opening to the wire cavity1341. Accordingly, the end1345of the wire retainer1340and a surface of the protrusion1346may create a v-shaped opening to the wire cavity1341and may act to funnel wires into the wire cavity1341through the opening. Additionally, as force is applied to the end1345of the wire retainer1340with a wire, the force may push the end1345of the wire retainer1340away from the protrusion1346and allow passage of the wire into the wire cavity1341. After the wire has been located within the wire cavity1341, the wire retainer1340may resiliently return to its original shape and location, which may prevent the wire from exiting the wire cavity1341without a force being applied to the wire retainer1340sufficient to deform the wire retainer1340.

In view of the foregoing, the wire retainer1340may accommodate a plurality of wires of a variety of sizes within the wire cavity1341, which may be inserted and/or removed from the wire cavity1341of the wire retainer1340individually (e.g., one at a time) or all at once.

FIG.13Billustrates a side view of the multifunction spacer-wire clip1300. The thickness of the main body portion1310may be selected to provide a target spacing between solar panels stacked upon one another during shipping. Furthermore, the spacer-wire clip1300may be manufactured with a shock absorptive polymer, plastic, and/or rubber to absorb shocks during shipping and maintain spacing to prevent scratching or other damage. In some embodiments, the external surface1313of the spacer-wire clip1300is in contact with adjacent solar panels during shipping (e.g., a top edge of a frame of an adjacent solar panel) and may be made from a polymer, plastic, and/or rubber selected to have target non-abrasive and/or impact absorption properties. In other embodiments, the external surface1313may include a polymer, plastic, and/or rubber coating or layer, selected to have target non-abrasive and/or impact absorption properties, that is a different material than the rest of the spacer-wire clip1300. The lower inside surface1322of the frame arm1320may likewise be made from, include a coating, or include a layer of a polymer, plastic, and/or rubber selected to have target non-abrasive and/or impact absorption properties.

In some embodiments, the entire spacer-wire clip1300may be a monolithic structure manufactured from a single material selected to retain wires within the wire cavity1341for many years, remain secured to the flange and frame of the solar panel for many years, and provide sufficient impact and/or abrasion protection during shipping. The spacer-wire clip1300may be manufactured using, for example, and without limitation, nylon, polyethylene, a composite nylon polyamide with polyethylene fibers, copolymer acetal, acetal homopolymer, polyamide, rubber-coated nylon, acrylate, or the like. In some embodiments, a removable or permanent rubber or foam layer may be applied to the external surface1313of the main body portion1310to increase the impact absorption properties of the spacer-wire clip1300.

FIG.13Cillustrates an isometric back view of the multifunction spacer-wire clip ofFIG.13A.

FIG.13Dillustrates a front view of the multifunction spacer-wire clip1300with example dimensions. The example dimensions are specifically selected based on the thickness and dimensions of the frame and flange of a particular solar panel. The exact dimensions, spacings, and thicknesses can be adapted and adjusted to accommodate solar panel frames and flanges of various shapes and sizes. Similarly, the dimensions, spacings, and thicknesses can be adapted and adjusted to accommodate a different number of wires and/or different thicknesses of wires.

FIG.13Eillustrates an end view of the multifunction spacer-wire clip1300with example dimensions.

FIG.13Fillustrates a perspective view of the multifunction spacer-wire clip1300next to a frame1390of a solar panel. The frame1390of the solar panel includes a flange1395.

FIG.13Gillustrates another perspective view of the multifunction spacer-wire clip1300flexing for placement on the flange1395of the solar panel, according to one embodiment. As described herein, the spacer-wire clip1300may be manufactured using one or more materials or composites of materials (homogenous or layered) that allow for the spacer-wire clip1300to be deformably flexed during installation and resiliently return to its original shape for long-term retention on the flange1395of the solar panel.

FIG.13Hillustrates another perspective view of the multifunction spacer-wire clip1300being placed on the flange1395of the solar panel, according to one embodiment. As illustrated, the edge of the flange1395enters the flange cavity1335, and the frame arm1320is flexed downward to extend beyond the edge of the frame1390.

FIG.13Iillustrates another perspective view of the multifunction spacer-wire clip1300secured to the flange1395of the solar panel, according to one embodiment. As illustrated, the flange1395is positioned within the flange cavity1335and the upper portion of the frame arm1320is secured to the outer surface of the frame1390.

FIG.14Aillustrates an isometric view of a multifunction spacer-wire clip1400with multiple wire cavities1441each configured to accommodate a wire, according to an additional embodiment. As illustrated, the spacer-wire clip1400includes a main body portion1410, having an upper surface1411, and an opposing external surface1413. The upper surface1411of the main body portion1410may contact an external surface of a flange of a solar panel during installation. The main body portion1410may be sized and positioned to space an external surface of the flange of the solar panel from an adjacent solar panel and prevent direct contact between the solar panel and the adjacent solar panel when the solar panel is positioned adjacent to the other solar panel in a stacked arrangement.

The spacer-wire clip1400may include a central part line1414from which surfaces of the spacer-wire clip1400may be tapered to facilitate the removal of the spacer-wire clip1400from a mold (e.g., and injection mold) during the manufacture of the spacer-wire clip. Additionally, edges of the spacer-wire clip1400may be rounded to aid in manufacturing (e.g., to ease in machining of a mold and/or to prevent short shots in an injection molding process) and/or to provide smooth edges to prevent scratching of solar panels by operators handling the spacer-wire clip1400.

A flange overhang portion1430may define a flange cavity1435sized and configured to receive a portion of a flange of a solar panel. The flange cavity1435may be defined between the upper surface1411of the main body portion1410and the flange overhang portion1430. Accordingly, an inner edge of the flange of a solar panel may be inserted within the flange cavity1435such that the flange overhang portion1430may be secured against the inner surface of the flange of the solar panel and the upper surface1411of the main body portion1410may be secured against the external surface of the flange of the solar panel. The edge of the flange of the solar panel may contact the inner surface of a connecting wall1432connecting the flange overhang portion1430to the main body portion1410of the spacer-wire clip1400.

A frame arm portion1420may extend perpendicular to the main body portion1410at an end of the main body portion1410, The frame arm portion1420comprises a surface sized and located to be positioned against an outer perimeter of the frame of the solar panel and prevent the portion of the flange from removal from the flange cavity1435when the frame arm portion1420is positioned against the outer perimeter of the frame. Accordingly, the upper inside surface1421of the frame arm portion1420may contact the outer perimeter of a frame of a solar panel during installation, as described and illustrated in greater detail below.

The frame arm portion1420may comprise a first portion1426extending perpendicular to the main body portion1410at a first end of the main body portion1410, the first portion1426positioned to be adjacent to a solar panel when the spacer-wire clip1400is installed on the solar panel. The frame arm portion1420may further comprise a second portion1428extending perpendicular to the main body portion1410at the first end of the main body portion1410and in a direction opposite the first portion1426, the second portion1428positioned to be adjacent an edge of an adjacent solar panel when the spacer-wire clip1400is installed on a solar panel and the solar panel is positioned adjacent to another solar panel in a stacked arrangement.

The main body portion1410may continue past the connecting wall1432in the same plane (as illustrated) or at an angle relative to a body extension1412connected to a wire retainer1440. The wire retainer1440may include arms1455extending from the body extension1412to form multiple wire cavities1441(e.g., two wire cavities1441). Accordingly, the wire cavities1441of the wire retainer1440extending from the main body portion1410may be sized and configured to selectively retain a wire in a respective wire cavity1441. As shown, each wire cavity1441may be configured to receive and retain a wire of the solar panel and/or other data or power cables routed to, from, or past the solar panel.

In the illustrated embodiment, each wire cavity1441may be defined by an arcuate surface of a curved wall1443specifically selected to accommodate a wire having a known diameter or wires having specific diameter ranges. Accordingly, each wire cavity1441may be defined by an arcuate surface with an inner radius substantially matching an outer radius of a wire of a solar panel.

Each wire cavity1441of the wire retainer1440may be configured to open to allow the insertion of at least one wire into the wire cavity1441in response to applying a force to the wire retainer1440with the at least one wire. The wire retainer1440may be configured to resiliently return to a closed position after a wire is positioned within a respective wire cavity1441. Additionally, one or more protrusions located at an opening into a respective wire cavity1441may be positioned to provide resistance to the removal of a wire from the respective wire cavity1441after the wire is positioned therein.

In view of the foregoing, the wire retainer1440may accommodate a plurality of wires, each within a respective wire cavity1441, which may be inserted and/or removed from the respective wire cavity1441of the wire retainer1440without first removing and/or inserting another wire from its respective wire cavity1441.

FIG.14Billustrates an isometric front view of the multifunction spacer-wire clip1400. The thickness of the main body portion1410may be selected to provide a target spacing between solar panels stacked upon one another during shipping. Furthermore, the spacer-wire clip1400may be manufactured with a shock absorptive polymer, plastic, and/or rubber to absorb shocks during shipping and maintain spacing to prevent scratching or other damage. In some embodiments, the external surface1413of the spacer-wire clip1400is in contact with adjacent solar panels during shipping (e.g., a top edge of a frame of an adjacent solar panel) and may be made from a polymer, plastic, and/or rubber selected to have target non-abrasive and/or impact absorption properties. In other embodiments, the external surface1413may include a polymer, plastic, and/or rubber coating or layer, selected to have target non-abrasive and/or impact absorption properties, that is a different material than the rest of the spacer-wire clip1400. A lower inside surface1422of the frame arm1420may likewise be made from, include a coating, or include a layer of a polymer, plastic, and/or rubber selected to have target non-abrasive and/or impact absorption properties.

In some embodiments, the entire spacer-wire clip1400may be a monolithic structure manufactured from a single material selected to retain wires within the wire cavities1441for many years, remain secured to the flange and frame of the solar panel for many years, and provide sufficient impact and/or abrasion protection during shipping. The spacer-wire clip1400may be manufactured using, for example, and without limitation, nylon, polyethylene, a composite nylon polyamide with polyethylene fibers, copolymer acetal, acetal homopolymer, polyamide, rubber-coated nylon, acrylate, or the like. In some embodiments, a removable or permanent rubber or foam layer may be applied to the external surface1413of the main body portion1410to increase the impact absorption properties of the spacer-wire clip1400.

FIG.14Cillustrates a side view of the multifunction spacer-wire clip1400with example dimensions.

FIG.14Dillustrates a front view of the multifunction spacer-wire clip1400with example dimensions.

FIG.14Eillustrates an end view of the multifunction spacer-wire clip1400with example dimensions.

FIG.14Fillustrates a perspective view of the multifunction spacer-wire clip1400next to a frame1490of a solar panel. The frame1490of the solar panel includes a flange1495.

FIG.14Gillustrates another perspective view of the multifunction spacer-wire clip1400flexing for placement on the flange1495of the solar panel, according to one embodiment. As described herein, the spacer-wire clip1400may be manufactured using one or more materials or composites of materials (homogenous or layered) that allow for the spacer-wire clip1400to be deformably flexed during installation and resiliently return to its original shape for long-term retention on the flange1495of the solar panel.

FIG.14Hillustrates another perspective view of the multifunction spacer-wire clip1400being placed on the flange1495of the solar panel, according to one embodiment. As illustrated, the edge of the flange1495enters the flange cavity1435, and the frame arm1420is flexed downward to extend beyond the edge of the frame1490.

FIG.14Iillustrates another perspective view of the multifunction spacer-wire clip1400secured to the flange1495of the solar panel, according to one embodiment. As illustrated, the flange1495is positioned within the flange cavity1435and the upper portion of the frame arm1420is secured to the outer surface of the frame1490.

In view of the foregoing, multifunctional spacer-wire clips according to embodiments of the present disclosure may be utilized for both packaging solar panels and installing solar panels.

For example, a solar panel may be packaged by coupling a plurality of spacer-wire clips (e.g., spacer-wire clips500,700,800,900,1000,1100,1200,1220,1240,1260,1280,1300, and/or1400) to a flange of a solar panel, such as by inserting a portion of the flange into a flange cavity of each of the plurality of spacer-wire clips. To secure the wires during shipping and handling, at least one wire of the solar panel may be positioned in a wire retainer of at least one of the plurality of spacer-wire clips, such as by applying a force with the at least one wire to a protrusion at an opening of a wire cavity and forcing the at least one wire past the protrusion into the wire cavity. The solar panel may be placed in a stack of solar panels where the solar panel may be spaced from an adjacent solar panel with the plurality of spacer-wire clips.

A solar panel installer may then install the solar panel by obtaining the stack of solar panels including the solar panel with the plurality of spacer-wire clips attached spacing the solar panel from an adjacent solar panel in a stack of solar panels. After obtaining the stack of solar panels the solar panel may be separated from the adjacent solar panel and placed in its working location (e.g., on a roof). An operator may then route one or more wires in their final installed location by inserting at least one wire into a cavity of a wire retainer of at least one spacer-wire clip of the plurality of spacer-wire clips and secure the one or more wires relative to the solar panel.

This disclosure contemplates a general multifunction spacer-wire clip that includes, in broad terms, (i) securing features to secure the spacer-wire clip to the flange of a solar panel, (ii) spacer features to space the solar panel from other solar panels in a stack of solar panels during shipping, where the spacer features function to protect the solar panel during shipping, and (iii) wire retaining features to retain at least one wire during installation and usage of the solar panel. The specific securing features, spacing features, and retaining features in the illustrated spacer-wire clips are merely examples of such features. It is contemplated that the relative dimensions, specific dimensions, and relative positioning of each of the three general features may be adapted and modified to fit a particular solar panel and/or to attain target positioning or performance characteristics.

The variously described embodiments of spacer-wire clips reduce or eliminate waste that is normally generated during the solar panel shipping process, including disposable spacer clips, zip ties, tape, and/or other packaging materials. A single spacer-wire clip performs the functions of a traditional spacer clip and a traditional wire clip, with improved performance and reliability. Additionally, embodiments of the spacer-wire clips that include dual-direction frame arms prevent stacked solar panels from shifting relative to one another during transportation.

While specific embodiments and applications of the disclosure have been illustrated and described, it is to be understood that the disclosure is not limited to the precise configurations and components disclosed herein. Accordingly, many changes may be made to the details of the above-described embodiments without departing from the underlying principles of this disclosure. The specific angles, lengths, widths, thicknesses, surface features, friction components, deformation characteristics, and/or impact absorption characteristics of the spacer-wire clips may be adjusted for a particular application. The scope of this patent application and the described inventions encompasses the illustrated examples, the various embodiments as described, the variations set forth above, the variations that would be apparent to those of skill in the art, and those embodiments encompassed by the following claims.