Clip fastener for photovoltaic system

• US 8,701,372 B2
• Filed: 12/02/2011
• Issued: 04/22/2014
• Est. Priority Date: 12/02/2011
• Status: Active Grant

• Current Assignee: Eaton Intelligent Power Limited (Eaton Corporation PLC.)
• Original Assignee: Cooper Technologies Company (Eaton Corporation PLC.)
• Inventors: Nuernberger, Eric Roland, McCarthy, William E.
• Primary Examiner(s): Gilbert, William
• Assistant Examiner(s): FORD, GISELE D
• Application Number:
  US13/310,404
• Publication Number:
  US 20130139869A1
• Time in Patent Office: 872 Days
• Field of Search: 521/733, 521/677, 521/678, 524/891, 524/892, 527/471, 257/433, 126/621, 126/622, 126/623, 248/121, 248/122.1, 136/251, 136/244, 136/291
• US Class Current: 52/747.1
• CPC Class Codes: E04F 19/06 specially designed for securing panels or masking the edges of wall- or floor-covering elements E04F19/022, E04F19/026 and E04F19/04 take precedence
• CPC Class Codes: E04F 2201/0115 with snap action of the edge connectors
• CPC Class Codes: F24S 25/12 using posts in combination with upper profiles
• CPC Class Codes: F24S 25/35 by means of profiles with a cross-section defining separate supporting portions for adjacent modules
• CPC Class Codes: F24S 25/636 clamping by screw-threaded elements
• CPC Class Codes: F24S 25/70 with means for adjusting the final position or orientation of supporting elements in relation to each other or to a mounting surface; with means for compensating mounting tolerances
• CPC Class Codes: H02S 20/00 Supporting structures for PV modules
• CPC Class Codes: H02S 20/10 Supporting structures directly fixed to the ground H02S20/30 takes precedence
• CPC Class Codes: H02S 20/24 specially adapted for flat roofs
• CPC Class Codes: Y02B 10/10 Photovoltaic [PV]
• CPC Class Codes: Y02E 10/47 Mountings or tracking
• CPC Class Codes: Y02E 10/50 Photovoltaic [PV] energy
• CPC Class Codes: Y10T 29/49355 Solar energy device making

Abstract

A photovoltaic system includes a photovoltaic module including a plurality of photovoltaic cells, and a frame surrounding the photovoltaic cells. The frame includes a lower flange. A module rail includes a module-support portion supporting the lower flange of the photovoltaic module. A clip fastener defines a press-fit channel in which the lower flange of the photovoltaic module and the module-support portion of the module rail are press fit to secure the module to the module-support portion of the module rail.

Claims

1. A method of assembling a photovoltaic system comprising:

supporting a photovoltaic module on a module-support portion of a module rail, the photovoltaic module including a frame having a lower flange;

press fitting the module-support portion of the module rail and the lower flange of the photovoltaic module into a press-fit channel of a clip fastener to secure the photovoltaic module on the module-support portion of the module rail.

2. The method set forth in claim 1, further comprising piercing an electrically non-conductive outer layer of the lower flange of the photovoltaic module with an electrically conductive piercing member of the clip fastener as the lower flange is press fit into the press-fit channel so that the piercing member contacts an electrically-conductive material disposed below the non-electrically-conductive outer layer.

6. The photovoltaic system set forth in claim 1, wherein the clip fastener includes a channel base, the first and second clip jaws extending outward from the channel base to define the press-fit channel and a throat of the press-fit channel, wherein the piercing member extends into the throat of the press-fit channel.

7. The photovoltaic system set forth in claim 6, wherein the piercing member includes at least one tooth integrally formed with the first clip jaw, the at least one tooth extending toward the channel base and into the throat at an acute angle relative to the first clip jaw.

8. The photovoltaic system set forth in claim 7, wherein the first and second clip jaw are resiliently deflectable away from one another about respective bend lines at the junctures between the first and second clip jaws and the channel base.

9. The photovoltaic system set forth in claim 8, wherein the clip fasteners is a one-piece and integrally formed from a single sheet of electrically conductive material.

3. A photovoltaic system comprising:

a photovoltaic module including a plurality of photovoltaic cells, and a frame surrounding the photovoltaic cells, the frame including a lower flange;

a module rail including a module-support portion supporting the lower flange of the photovoltaic module; and

a clip fastener defining a press-fit channel in which the lower flange of the photovoltaic module and the module-support portion of the module rail are press fit to secure the module to the module-support portion of the module rail.

4. The photovoltaic system set forth in claim 3, wherein the clip fastener includes at least first and second clip jaws at least partially defining the press-fit channel, wherein at least one of the first and second clip jaws is resiliently deflectable generally away from the other of the first and second clip jaws as the lower flange of the photovoltaic module and the module-support portion of the module rail are press fit into the press-fit channel to facilitate securement of the module to the module rail.

5. The photovoltaic system set forth in claim 4, wherein the lower flange has an electrically non-conductive outer layer covering an electrically conductive material, the clip fastener including a piercing member extending from the first clip jaw into the press-fit channel and through the electrically non-conductive outer layer of the lower flange so that the piercing member is in contact with the electrically conductive material.

10. The photovoltaic system set forth in claim 4, wherein the module rail includes a sidewall extending downward from the module-support portion, the sidewall having at least one clip-fastener opening extending through the sidewall adjacent the module-support portion, wherein the first clip jaw engages the lower flange of the photovoltaic module and the second clip jaw is received in the clip-fastener opening and engages an underside of the module-supporting surface.

11. The photovoltaic system set forth in claim 10, wherein the clip fastener includes a depth stop on the second clip jaw that inhibits further advancement of the second clip jaw into the clip fastener opening.

12. The photovoltaic system set forth in claim 11, wherein the depth stop is configured to contact an exterior surface of the sidewall.

13. The photovoltaic system set forth in claim 10, wherein the clip fastener includes a withdrawal stop on the second clip jaw that inhibits withdrawal of the second clip jaw from the clip fastener opening.

14. The photovoltaic system set forth in claim 13, wherein the withdrawal stop is configured to contact an interior surface of the sidewall.

15. The photovoltaic system set forth in claim 3, wherein the lower flange has an electrically non-conductive outer layer covering an electrically conductive material, the clip fastener including a piercing member extending into the press-fit channel and through the electrically non-conductive outer layer of the lower flange so that the piercing member is in contact with the electrically conductive material.

16. A racking assembly for a photovoltaic system, the racking assembly comprising:

a module rail on which at least one photovoltaic module is securable, the module rail including a module-support portion for supporting the photovoltaic module; and

a clip fastener for securing the photovoltaic module to the module rail, the clip fastener defining a press-fit channel for press fitting a lower flange of the photovoltaic module and the module-support portion of the module rail therein to secure the module to the module rail.

17. The racking assembly set forth in claim 16, wherein the clip fastener includes upper and lower clip jaws partially defining the press-fit channel, wherein at least one of the upper and lower clip jaws is resiliently deflectable generally away from the other of the upper and lower clip jaws as the lower flange of the photovoltaic module and the module-support portion of the module rail are press fit into the press-fit channel.

18. The racking assembly set forth in claim 16, wherein the clip fastener includes a piercing member extending into the press-fit channel, the piercing member configured to pierce an electrically non-conductive outer layer of the lower flange so that the piercing member is in contact with the electrically-conductive material below the outer layer.

19. A clip fastener for securing a photovoltaic module to a module rail of a racking assembly, the clip fastener comprising:

first and second clip jaws partially defining a press-fit channel for press fitting a lower flange of the photovoltaic module and a module-support portion of the module rail therein to secure the photovoltaic modules to the module rail, wherein at least one of the first and second clip jaws is resiliently deflectable generally away from the other of the first and second clip jaws as the lower flange of the photovoltaic module and the module-support portion of the module rail are press fit into the press-fit channel; and

a piercing member extending from the first clip jaw into the press-fit channel, the piercing member configured to pierce an electrically non-conductive outer layer of the lower flange so that the piercing member is in contact with an electrically-conductive material below the outer layer.

20. The clip fastener set forth in claim 19, further comprising a channel base, the first and second clip jaws extending outward from the channel base to define the press-fit channel and a throat of the press-fit channel, wherein the piercing member extends into the throat of the press-fit channel.

21. The clip fastener set forth in claim 20, wherein the piercing member includes at least one tooth integrally formed with the first clip jaw, the at least one tooth extending toward the channel base and into the throat at an acute angle relative to the first clip jaw.

22. The clip fastener set forth in claim 21, wherein the clip fasteners is a one-piece and integrally formed from an electrically conductive material.

23. The clip fastener set forth in claim 20, wherein the first and second clip jaws are resiliently deflectable away from one another about respective bend lines at the junctures between the first and second clip jaws and the channel base.

24. The clip fastener set forth in claim 19, further comprising depth stop extending downward from the second clip jaw to facilitate positioning of the clip fastener in a desired position on the photovoltaic module and the module rail as the lower flange of the photovoltaic module and the module-support portion of the module rail are press fit into the press-fit channel.

25. The clip fastener set forth in claim 19, further comprising a withdrawal stop extending downward from the second clip jaw to inhibit withdrawal of the clip fastener from the lower flange of the photovoltaic module and the module-support portion of the module rail when the clip fastener is positioned in a desired position on the photovoltaic module and the module rail.