Adjustable End Clamp for Mounting Solar Panels to Roofs

• US 20170302221A1
• Filed: 04/15/2016
• Published: 10/19/2017
• Est. Priority Date: 04/15/2016
• Status: Active Grant

• Current Assignee: Sunmodo Corporation
• Original Assignee: Sunmodo Corporation
• Inventors: Jasmin, Roland
• Granted Patent: US 9,876,463 B2
• Time in Patent Office: Days
• CPC Class Codes: F24S 2025/6007 by using form-fitting connection means, e.g. tongue and groove
• CPC Class Codes: F24S 2025/6008 by using toothed elements
• CPC Class Codes: F24S 25/632 Side connectors; Base connectors
• CPC Class Codes: F24S 25/636 clamping by screw-threaded elements
• CPC Class Codes: F24S 25/65 for coupling adjacent supporting elements, e.g. for connecting profiles together
• CPC Class Codes: H02S 20/23 specially adapted for roof structures
• CPC Class Codes: H02S 30/00 Structural details of PV modules other than those related to light conversion semiconductor device aspects of modules of electrolytic light sensitive devices H01G9/20, of inorganic PV modules H01L31/00, of organic PV modules H10K30/00
• CPC Class Codes: H02S 30/10 Frame structures
• CPC Class Codes: Y02B 10/10 Photovoltaic [PV]
• CPC Class Codes: Y02B 10/20 Solar thermal
• CPC Class Codes: Y02E 10/47 Mountings or tracking
• CPC Class Codes: Y02E 10/50 Photovoltaic [PV] energy

Abstract

Disclosed is a system and device (10, 100, 200, 300) for mounting a solar panel (11) to a roof (43). The device (10, 100, 200, 300) allows for the mounting of solar panels (11) with various thicknesses using an end clamp (12) and base (13) assembly where the end clamp (12) is height adjustable along an alignment portion (20) that projects vertically upward from a planar top surface (19) of the base (13). The end clamp (12) includes an end portion (18) with a three-angle bearing surface (27) that engages both a side surface and a groove (23) within a side surface of the alignment portion (20). The solar panel (11) frame is secured from the top by an upper clamping surface of the end clamp (12) to the alignment portion (20) and the top surface of the base (13).

Claims

1. A device (10, 100, 200, 300) for mounting a solar panel (11) to a roof (43), comprising:

a base (13) including a planar top surface (19) and an alignment portion (20) projecting directly and perpendicularly upward from the planar top surface (19);

an end clamp (12) including an upper clamping portion (16) positioned above the alignment portion (20), a mid-portion (17) projecting directly downward from the upper clamping portion (16), and an end portion (18) projecting directly and obliquely away from the mid-portion (17) and toward the alignment portion (20);

the end portion (18) includes an upward facing outside surface (31), a downward facing outside surface (32), and a three-angle bearing surface (27) that engages co-planarly against both a first outside surface (21) and a groove (23) extending longitudinally within the first outside surface (21) of the alignment portion (20);

the three-angle bearing surface (27) includes a first planar bearing surface (28) that directly and obliquely extends from the upward facing outside surface (31) and aligns vertically against the first outside surface (21) of the alignment portion (20), a second planar bearing surface (29) that directly and obliquely extends from the first planar bearing surface (28), and a third planar bearing surface (30) that extends directly and at an angle of 90-degrees or less with respect to the second planar bearing surface (29) and terminating at the downward facing outside surface (32) making an oblique angle therewith;

a threaded fastener (14) projecting through the planar top surface (19) and the alignment portion (20) secures the upper clamping portion (16) to the base (13); and

the upper clamping portion (16) engages and secures the solar panel (11) co-planarly against the planar top surface (19) and a second outside surface (22) of the alignment portion (20).

3. The device (10, 100, 200, 300) of claim 1, wherein:

the first outside surface (21) and the second outside surface (22) each include two or more grooves (23) complementary in shape to the second planar bearing surface (29) and the third planar bearing surface (30) in combination; and

each groove (23) of the two or more grooves (23) is positioned at a unique distance above the planar top surface (19).

4. The device (10, 100, 200, 300) of claim 1 further comprising:

a hollow bolt (15) including a bolt body (39), the bolt body (39) including an unthreaded exterior surface and a threaded aperture (41) therein, the bolt body projecting downward through the upper clamping portion; and

the threaded fastener (14) projecting upward through the alignment portion (20) and threadably engaging the threaded aperture (41).

5. The device (10, 100, 200, 300) of claim 4, wherein:

the alignment portion (20) includes a closed planar top surface with and aperture therethrough; and

the aperture (53) sized and shaped to receive the bolt body (39) therein.

6. The device (10, 100, 200, 300) of claim 1, further comprising:

a hollow bolt (15) including a bolt body (39), the bolt body (39) including an unthreaded exterior surface and a threaded aperture (41) therein, the bolt body (39) projecting downward through the upper clamping portion (16); and

the threaded fastener (14) projecting upward through the alignment portion (20) and threadably engaging the threaded aperture (41).

7. The device (10, 100, 200, 300) of claim 6, wherein:

the alignment portion (20) includes a closed planar top surface with and aperture therethrough; and

the aperture (53) sized and shaped to receive the bolt body (39) therein.

2. (canceled)

8. A device (10, 100, 200, 300) for mounting a solar panel (11) to a roof (43) comprising:

a base (13) including a planar top surface (19) and an alignment portion (20);

the alignment portion (20) including a first outside surface (21) and a second outside surface (22) each projecting directly and perpendicularly upward from the planar top surface (19) and dividing the planar top surface (19) into a first top surface portion and a second top surface portion, the first outside surface (21) including a groove (23) extending longitudinally therein;

an end clamp (12) including an upper clamping portion (16) extending above the alignment portion (20) and over the first top surface portion and the second top surface portion, a mid-portion (17) projecting directly from the upper clamping portion (16) and downward toward the first top surface portion, and an end portion (18) projecting directly and obliquely away from the mid-portion (17) and toward the first outside surface (21);

a threaded fastener (14) including a body projecting upward into the base (13) and the upper clamping portion (16);

the end portion (18) including an upward facing outside surface (31) and a downward facing outside surface (32), the end portion (18) terminates in a three-angle bearing surface (27);

the three-angle bearing surface (27) includes a first planar bearing surface (28) that directly and obliquely extends from the upward facing outside surface and aligns vertically against the first outside surface (21) of the alignment portion (20), a second planar bearing surface (29) that directly and obliquely extends from the first planar bearing surface (28), and a third planar bearing surface (30) that extends directly and at an angle of 90-degrees or less with respect to the second planar bearing surface (29) and terminating at an oblique angle with respect to the downward facing outside surface (32); and

the groove (23) is complementary shaped to the second planar bearing surface (29) and the third planar bearing surface (30) in combination, and the groove (23) receives the second planar bearing surface (29) and the third planar bearing surface (30) therein.

9. The device (10, 100, 200, 300) of claim 8, wherein:

the first outside surface (21) and the second outside surface (22) each include two or more grooves (23) complementary in shape to the second planar bearing surface (29) and the third planar bearing surface (30) in combination; and

each groove (23) of the two or more grooves (23) is positioned at a unique distance above the planar top surface (19).

10. The device (10, 100, 200, 300) of claim 8 further comprising:

a hollow bolt (15) including a bolt body (39), the bolt body (39) including an unthreaded exterior surface and a threaded aperture (41) therein, the bolt body projecting downward through the upper clamping portion; and

the threaded fastener (14) projecting upward through the alignment portion (20) and threadably engaging the threaded aperture (41).

11. The device (10, 100, 200, 300) of claim 10, wherein:

the alignment portion (20) includes a closed planar top surface with and aperture (53) therethrough; and

the aperture (53) sized and shaped to receive the bolt body (39) therein.