CLAMPS FOR SECURING SOLAR ENERGY PANELS

• US 20160111996A1
• Filed: 10/19/2015
• Published: 04/21/2016
• Est. Priority Date: 10/20/2014
• Status: Active Grant

• Current Assignee: Pegasus Solar Inc.
• Original Assignee: Pegasus Solar Inc.
• Inventors: Stephan, Erich Kai, Harris, Glenn
• Granted Patent: US 9,660,570 B2
• Time in Patent Office: Days
• US Class Current: 1/1
• CPC Class Codes: F16B 2/065 using screw-thread elements F16B2/08 - F16B2/12 take precedence
• CPC Class Codes: F16B 2005/0678 in abutting relationship
• CPC Class Codes: F16B 5/0028 using I-shaped connectors with flanges moving towards each other F16B5/0068
• CPC Class Codes: F16B 5/0685 Joining sheets or plates to strips or bars F16B5/0692 takes precedence
• CPC Class Codes: H02S 20/20 Supporting structures directly fixed to an immovable object H02S20/30 takes precedence
• CPC Class Codes: H02S 20/23 specially adapted for roof structures
• CPC Class Codes: Y02B 10/10 Photovoltaic [PV]
• CPC Class Codes: Y02E 10/50 Photovoltaic [PV] energy

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.

Claims

1. A solar panel clamp assembly comprising:

a top clamp comprising;

a substantially planar plate, a first top flange extending away from the plate, and a second top flange extending away from the plate in a direction substantially parallel to the plane and in substantially the opposite direction than the first top flange; and

a top clamp aperture disposed through the plate and the geometric protrusion; and

a bottom clamp comprising;

a base member having a top surface and a lower surface;

a first base flange extending away from the lower surface of the base member and a second base flange extending away from the lower surface of the base member in substantially the opposite direction than the first base flange; and

a bottom clamp aperture extending through the base member,

wherein the top clamp and the bottom clamp are clamped together when a fastener extends through the top clamp aperture and the bottom clamp aperture a nut is turned on the fastener.

2. The solar panel clamp assembly of claim 1, wherein the first top flange is substantially symmetrical to the second top flange, and wherein the first base flange is substantially symmetrical to the second base flange.

3. The solar panel clamp assembly of claim 1, wherein the first base flange is substantially parallel with the plane of the plate, wherein the second base flange is angled upward toward the top clamp such that the interface between the second base flange and the plate is lower than the interface between the first base flange and the plate.

4. The solar panel clamp assembly of claim 3, where in the second base flange has a gentle curvature to reduce point stresses on an installed solar energy panel.

5. The solar panel clamp assembly of claim 3, wherein the second base flange is displaced downward, thereby compressing the frame of the solar panel when a solar panel is inserted between the top clamp and the bottom clamp.

6. The solar panel clamp assembly of claim 3, wherein the top surface of the bottom clamp further comprises an upward facing protrusion on the side of the second base flange, wherein the upward facing protrusion is configured to engage a bottom surface of the plate when a solar panel is clamped between the first top flange and the first base flange, thereby acting as a fulcrum to allow for clamping the top clamp and bottom clamp with only one solar panel installed while preventing the top clamp from being angled askew with respect to the bottom clamp.

7. The solar panel clamp assembly of claim 1, wherein the top clamp aperture and bottom clamp aperture comprise 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.

8. The solar panel clamp assembly of claim 1, wherein the first and second flanges taper in cross-sectional area as they extend from the center, thereby reducing point stresses on a supported solar energy panel.

9. The solar panel clamp assembly of claim 1, wherein the first flange has a groove for supporting electrical wiring.

10. A clamp assembly for mounting solar panels and accessories comprising:

a top clamp comprising;

a substantially planar plate;

a first raised flange on a first terminal edge of a surface that extends upwards from the plane and away from the plate;

a second raised flange on a second terminal edge of the surface substantially opposite from the first terminal edge that extends upwards from the plane and away from the plate and in substantially the opposite direction than the first raised flange;

a geometric protrusion extending downward from the plate; and

a top clamp aperture disposed through the plate and the geometric protrusion;

a bottom clamp comprising;

a base member having a lower surface and top surface with a geometric cavity disposed therein;

a first base flange extending away from the lower surface of the base member;

a second base flange extending away from the lower surface of the base member in substantially the opposite direction than the first base flange; and

a bottom clamp aperture extending through the base member and the geometric cavity;

a fastener extending through the top clamp aperture and the bottom clamp aperture; and

a nut that, when turned on the fastener, causes the fastener and the nut to compress the top clamp and bottom clamp together,

wherein the top clamp and the bottom clamp are configured to freely rotate about the fastener relative to each other when the geometric protrusion is not compressed within the geometric cavity, and

wherein the first raised flange and the second raise flange respectively align above the first base flange or the second base flange when the geometric protrusion is compressed within the geometric cavity.

11. The clamp assembly of claim 10, wherein the first raised flange and the second raised flange extend away from the plate in a direction that creates a minor acute angle with an axis substantially orthogonal to the plane, and wherein the first raised flange and the second raised flange are configured to displace to a position that is substantially parallel to the plane when a solar panel module is compressed between the top clamp and bottom clamp.

12. The clamp assembly of claim 10, wherein the first raised flange is substantially symmetrical to the second raised flange, and wherein the first base flange is substantially symmetrical to the second base flange.

13. The clamp assembly of claim 10, wherein the first base flange is substantially parallel with the plane of the plate, wherein the second 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, and wherein the second base flange is displaced downward to become substantially parallel with the plane of the plate when a solar panel is inserted between the top clamp and the bottom clamp.

14. The clamp assembly of claim 10, wherein a lower surface of the first raised flange and a lower surface of the second raised flange each include a plurality of grooves for increasing the friction on a solar panel clamped between the top clamp and the bottom clamp.

15. The clamp assembly of claim 10, wherein the first flange has a groove for supporting electrical wiring.

16. The clamp assembly of claim 10, wherein an upper surface of the first base flange and an upper surface of the second base flange each include one or more 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.

17. The clamp assembly of claim 10, wherein a bottom surface of the plate and the top surface of the bottom clamp act as two additional clamping surfaces on either side of the fastener when the geometric protrusion is compressed within the geometric cavity.

18. The clamp assembly of claim 10, wherein the top surface of the bottom clamp further comprises a pair of upward facing protrusions on either side of the geometric cavity, wherein each of the upward facing protrusions are configured to engage a bottom surface of the plate on a first side of the geometric cavity when a solar panel is clamped between the first raised flange and the first base flange or the second base on the other side of the geometric cavity, thereby reducing torque on the fastener.

19. A clamp assembly comprising:

a bottom clamp comprising;

a substantially flat bottom plate having a bottom plate aperture and a first terminal edge having a vertically disposed lip; and

a vertically disposed main body having a top surface substantially planar with the bottom plate, having a geometric cavity in the top surface with a vertical protrusion above the top surface, and having a main body aperture positioned in the geometric cavity projected substantially above the bottom plate aperture;

a top clamp comprising;

a substantially flat plate having a geometric protrusion on a bottom side of the top clamp, wherein a top clamp aperture is positioned in the geometric protraction;

an offset flange on a terminal edge of the flat plate; and

a fastener system comprising;

a bolt inserted through the bottom plate aperture, through the main body aperture, and through the top clamp aperture such that a terminal portion of the bolt is accessible from a top side of the top clamp; and

a nut configured to thread onto the terminal portion of the bolt, thereby drawing the top clamp and the bottom clamp together, such that as the geometric protrusion mates with the geometric cavity, the vertical protrusion of the geometric cavity acts as a fulcrum for the top clamp relative to the bottom clamp.

20. The clamp assembly of claim 19, wherein the vertical protrusions cause a channel to be formed between the top clamp and the bottom clamp when the geometric protrusion is fully mated with the geometric cavity.

21. The clamp assembly of claim 20, wherein the top surface of the main body has ridges disposed thereon, wherein the ridges are contained in the channel.

22. The clamp assembly of claim 20, wherein a bottom surface of the top clamp has ridges disposed thereon, wherein the ridges are contained in the channel.

23. The clamp assembly of claim 20, wherein the channel is configured to clamp a wind deflector, and wherein the lip is configured to support an angled bend of the wind deflector.

24. A solar panel clamp assembly comprising:

a top clamp comprising;

a substantially planar plate, a first top flange extending away from the plate, and a second top flange extending away from the plate in substantially the opposite direction than the first top flange; and

a top clamp aperture disposed through the plate and the geometric protrusion; and

a bottom clamp comprising;

at least two planar layers of sheet metal coupled together that form a bottom surface of the bottom clamp and that are configured such that at least two portions of a bottom layer are bent upwards in a direction orthogonal to the plane, the at least two portions of the bottom layer forming a top clamp supporting surface; and

a bottom clamp aperture extending through two planar layer,

wherein the top clamp and the bottom clamp are clamped together when a fastener extends through the top clamp aperture and the bottom clamp aperture a nut is turned on the fastener.