End clamp for mounting solar module to rail

Patent metadata

Field	Value
Publication number	US-10243507-B2
Application number	US-201715804167-A
Country	US
Kind code	B2
Filing date	Nov 6, 2017
Priority date	Jun 29, 2016
Publication date	Mar 26, 2019
Grant date	Mar 26, 2019

Abstract

A solar power system may include rails, solar modules, and a plurality of clamps to secure the solar modules to the rails. An end clamp may be partially disposed inside a rail at an end of the rail. The end clamp may secure a solar module to the rail by coupling to the frame of the solar module. The end clamp may include a fastener that may be tightened to engage the end clamp and secure the solar module by holding it on top of the rail. The end clamp may establish an electrical grounding connection between the frames of the solar module and the rail.

First claim

The invention claimed is:

1. A mounting system comprising:
a rail having an end, an interior top surface, an interior bottom surface, and an exterior top surface; and
an end clamp, at least a portion of the end clamp disposed inside the rail at the end of the rail, the end clamp comprising:
a fastener having a head end and a tail end;
a clamping plate configured to be disposed at least partially outside of the rail, wherein the clamping plate is adapted to secure a module to the rail, and
an inner member disposed inside of the rail, the inner member being positioned between a first surface of the clamping plate and a first interior surface of the rail, wherein

the tail end of the fastener is engaged with the inner member at a position inside of the rail to apply a first force in a first horizontal direction on the inner member, the head of the fastener is engaged with the clamping plate to apply a second force in a second horizontal direction on the clamping plate, and the inner member deflects the first force and second force onto the first interior surface of the rail causing the inner member to engage with the first interior surface of the rail.

2. The mounting system of claim 1 , wherein
the first surface of the clamping plate is an interior top surface of the clamping plate disposed inside of the rail.

3. The mounting system of claim 1 , wherein
the first interior surface of the rail is the interior top surface of the rail.

4. The mounting system of claim 1 , wherein
the end clamp includes an opening in a surface of the clamping plate disposed outside of the rail configured to receive the fastener.

5. The mounting system of claim 1 , wherein
the end clamp includes an opening in a surface of the clamping plate disposed inside of the rail configured to receive the fastener.

6. The mounting system of claim 1 , wherein
the inner member includes a threaded opening configured to be engaged with the tail end of the fastener.

7. The mounting system of claim 1 , wherein
the end clamp includes a first opening in a surface of the clamping plate disposed outside of the rail configured to receive the fastener,
the end clamp includes a second opening in a surface of the clamping plate disposed inside of the rail configured to receive the fastener, and
the inner member includes a threaded opening configured to be engaged with the tail end of the fastener.

8. The mounting system of claim 1 , wherein
the clamping plate includes an anodization layer.

9. The mounting system of claim 8 , wherein
the fastener comprises one or more grounding teeth configured to break the anodization layer.

10. The mounting system of claim 1 , wherein
the clamping plate includes a lip disposed outside of the rail and configured to engage with a frame of the module.

11. The mounting system of claim 1 , further comprising:
the module; and
a frame configured to support the module.

12. The mounting system of claim 11 , wherein
the frame includes an anodization layer.

13. The mounting system of claim 12 , wherein
the clamping plate includes a lip disposed outside of the rail and configured to engage with the frame.

14. The mounting system of claim 13 , wherein
the lip includes one or more grounding teeth configured to break the anodization layer of the frame.

15. The mounting system of claim 1 , wherein
the module is a solar module, and
the mounting system comprises
the solar module including a frame having a top, a bottom, and a channel disposed between the top and bottom, wherein at least a portion of the clamping plate is disposed inside the channel.

16. The mounting system of claim 1 , wherein
the inner member includes a threaded aperture, and
at least a threaded portion of the fastener is disposed within and engaged with the threaded aperture.

17. The mounting system of claim 1 , wherein
the module is a solar module including a frame, and
an electrical grounding path is established from the frame through the end clamp to the rail.

18. The mounting system of claim 17 , wherein
the electrical grounding path is established from the frame, through the clamping plate, through the fastener, through the inner member, to the rail.

19. A solar system comprising:
a rail having an end, an interior top surface, an interior bottom surface, and an exterior top surface;
a solar module including a frame; and
an end clamp, at least a portion of the end clamp disposed inside the rail at the end of the rail, the end clamp comprising:
a fastener having a head end and a tail end;
a clamping plate configured to be disposed at least partially outside of the rail and partially inside of the rail, wherein the clamping plate is adapted to secure the frame to the rail, and
an inner member disposed between and engaged with a top surface of the clamping plate inside of the rail and the interior top surface of the rail, wherein

the tail end of the fastener extends inside of the rail to engage with the inner member to apply a first force in a first horizontal direction on the inner member, the head of the fastener is engaged with the clamping plate to apply a second force in a second horizontal direction on the clamping plate, and the inner member deflects the first force and second force onto the top interior surface of the rail causing the inner member to engage with the first interior surface of the rail and apply a downward force to an exterior portion of the end clamp engaged with the frame of the solar module.

20. A solar system comprising:
a rail having an end, an interior top surface, an interior bottom surface, and an exterior top surface;
a solar module including a frame; and
an end clamp, at least a portion of the end clamp disposed inside the rail at the end of the rail, the end clamp comprising:
a fastener having a head end and a tail end, the tail end including a threaded portion;
a clamping plate configured to be disposed at least partially outside of the rail and partially inside of the rail, wherein the clamping plate is adapted to secure the frame to the rail, and

an inner member disposed between and engaged with a top surface of the clamping plate inside of the rail and the interior top surface of the rail, the inner member including a threaded aperture, wherein
at least a part of the threaded portion of the fastener is disposed within and engaged with the threaded aperture inside of the rail to apply a first force in a first horizontal direction on the inner member, the head of the fastener is engaged with the clamping plate to apply a second force in a second horizontal direction on the clamping plate, and the inner member deflects the first force and second force onto the top interior surface of the rail causing the inner member to engage with the first interior surface of the rail and apply a downward force to an exterior portion of the end clamp engaged with the frame of the solar module.

Assignees

• Sunpower Corp

Inventors

• Kapla John Paul
• Feldmann Kyle Donald
• Benjamin Dylan

Classifications

• H02S30/10

  Frame structures · CPC title

• Y02E10/50

  Photovoltaic [PV] energy · CPC title

• H02S20/23 Primary

  specially adapted for roof structures · CPC title

• F24S25/632

  Side connectors; Base connectors · CPC title

• F24S2025/014

  Methods for installing support elements · CPC title