Clamps for solar systems

Patent metadata

Field	Value
Publication number	US-10432133-B2
Application number	US-201615383757-A
Country	US
Kind code	B2
Filing date	Dec 19, 2016
Priority date	Dec 23, 2013
Publication date	Oct 1, 2019
Grant date	Oct 1, 2019

Abstract

A solar power system can include a rail and a solar module disposed on the rail. A clamp assembly can couple the solar module to the rail. The clamp assembly can have a clamped configuration in which the solar module is secured to the rail and an unclamped configuration. The clamp assembly can comprise an upper clamp member, a lower clamp member coupled to the rail, and a stabilization member mechanically engaging the upper clamp member and the lower clamp member. The stabilization member can prevent rotation of the lower clamp member relative to the rail when the clamp assembly is in the clamped and unclamped configurations. In the unclamped configuration, the stabilization member can be biased such that the upper clamp member is disposed at a sufficient clearance above the rail to permit the insertion of the solar module between the upper clamp member and the rail.

First claim

What is claimed is:

1. A method of assembling a solar array to a support structure, the method comprising:
mounting a rail to the support structure;
positioning a first solar module on the rail;
coupling a clamp assembly to the rail, the clamp assembly comprising an upper clamp member, a lower clamp member coupled to the rail, and a stabilization member biased such that the upper clamp member is disposed above the rail by a clearance, the stabilization member preventing rotation of the lower clamp member relative to the upper clamp member;
disposing the first solar module in the clearance between the upper clamp member and the rail;
translating the upper clamp member towards the rail to clamp an edge portion of the first solar module between the upper clamp member and the rail;
snapping a skirt clip to a frame of the first solar module; and
snapping a skirt segment to the skirt clip to couple the skirt segment to the first solar module,
wherein the skirt clip includes an upper member having a first distal end that connects to the frame of the first solar module and a second distal end that connects to the skirt segment, a lower member having a first distal end that connects to the frame of the first solar module and a second distal end that connects to the skirt segment, and a connecting member extending from the first distal end of the upper member to the second distal end of the lower member.

2. The method of claim 1 , wherein the rail has a groove along a length of the rail, wherein the lower clamp member comprises a lower body having a length and a width, the length larger than the width, and wherein coupling the clamp assembly to the rail comprises inserting the lower body into the groove of the rail such that the length of the lower body is substantially aligned with the length of the rail.

3. The method of claim 2 , wherein the coupling the clamp assembly to the rail comprises rotating the lower body such that the length of the lower body is transverse to the length of the rail, and such that a lower portion of the stabilization member engages the rail.

4. The method of claim 2 , wherein the lower clamp member comprises an arcuate contact ridge, and the rail comprises one or more ribs extending towards the lower clamp member.

5. The method of claim 4 , further comprising clamping the lower clamp member to the rail such that the arcuate contact ridge engages the one or more ribs to create one or more electrical connections between the lower clamp member and the rail.

6. The method of claim 1 , further comprising:
positioning a second solar module on the rail adjacent the first solar module;
disposing the second solar module in the clearance between the upper clamp member and the rail; and
translating the upper clamp member towards the rail to clamp the edge portion of the first solar module and an edge portion of the second solar module between the upper clamp member and the rail.

7. The method of claim 1 , further comprising mechanically coupling a fastener to the upper clamp member and the lower clamp member, and engaging the fastener to translate the upper clamp member towards the lower clamp member.

8. The method of claim 1 , further comprising engaging an upper portion of the stabilization member with the upper clamp member and engaging a lower portion of the stabilization member with the rail.

9. The method of claim 8 , wherein the stabilization member comprises a generally X-shaped cross-section, the stabilization member comprising a central portion having two upwardly-extending flanges and two downwardly-extending flanges extending therefrom.

10. The method of claim 1 , wherein the first solar module is disposed along a periphery of the solar array.

11. The method of claim 10 , wherein snapping the skirt clip comprises snapping a slot of the skirt clip to a corresponding lip of the first solar module.

12. The method of claim 9 , wherein the upper clamp member includes two arms each including a first portion extending outwardly from a major axis and a second portion extending downwardly along the major axis from the first portion, and the two upwardly-extending flanges extend outwardly from the major axis further than the two arms.

13. The method of claim 9 , wherein the upper clamp member includes two arms each including a first portion extending outwardly from a major axis and a second portion extending downwardly along the major axis from the first portion and ending in a support edge, and the two upwardly-extending flanges contact the support edges of the two arms.

14. The method of claim 9 , wherein the stabilization member includes a C-shaped channel facing the lower clamp member and the lower clamp member includes a locking nut positioned within the C-shaped channel of the stabilization member.

15. A method of assembling an array of solar modules, the method comprising:
forming an array of solar modules;
snapping a plurality of skirt clips to frames of the solar modules; and
snapping skirt segments to the plurality of skirt clips to couple the skirt segments to the solar modules,
wherein each of the skirt clips includes an upper member having a first end that connects to a corresponding frame of the solar modules and a second end that connects to a corresponding skirt segment, a lower member having a first end that connects to the corresponding frame of the solar modules and a second end that connects to the corresponding skirt segment, and a connecting member extending from the first end of the upper member to the second end of the lower member, the upper member being parallel to the lower member.

16. The method of claim 15 , wherein snapping the plurality of skirt clips comprises snapping slots of the skirt clips to corresponding lips of the solar modules.

17. The method of claim 15 , wherein snapping the skirt segments to the plurality of skirt clips comprises snapping slots of the skirt clips to corresponding lips of the skirt segments.

18. The method of claim 15 , wherein snapping the plurality of skirt clips comprises snapping the plurality of skirt clips to solar modules along a periphery of the array.

19. A solar array comprising:
a rail mounted to a support structure;
a first solar module positioned on the rail;
a clamp assembly coupled to the rail, the clamp assembly comprising an upper clamp member, a lower clamp member coupled to the rail, and a stabilization member biased such that the upper clamp member is disposed above the rail by a clearance, the stabilization member preventing rotation of the lower clamp member relative to the upper clamp member;
the first solar module being disposed in the clearance between the upper clamp member and the rail;
the upper clamp member being positioned towards the rail to clamp an edge portion of the first solar module between the upper clamp member and the rail;
a skirt clip coupled to a frame of the first solar module; and
a skirt segment coupled to the skirt clip, thereby coupling the skirt segment to the first solar module,
wherein the skirt clip includes an upper member having a first end that connects to the frame of the first solar module and a second end that connects to the skirt segment, a lower member having a first end that connects to the frame of the first solar module and a second end that connects to the skirt segment, and a connecting member extending from the first end of the upper member to the second end of the lower member, and
wherein the first end of the upper member is positioned directly above the first end of the lower mem

Assignees

• Sunpower Corp

Inventors

• Braunstein Ryan
• Kinyon Zachary
• Carre Guillaume
• Matrat David

Classifications

• Y02B10/20

  Solar thermal · CPC title

• H02S20/23 Primary

  specially adapted for roof structures · CPC title

• F24S25/30

  using elongate rigid mounting elements extending substantially along the supporting surface, e.g. for covering buildings with solar heat collectors (extending in directions away from the supporting surface F24S25/10; peripheral frames for modules F24S25/20) · CPC title

• Y10T29/49355

  Solar energy device making · CPC title

• F24S25/00

  Arrangement of stationary mountings or supports for solar heat collector modules · CPC title