Rail-based solar panel mounting system

Patent metadata

Field	Value
Publication number	US-12506436-B2
Application number	US-202418671607-A
Country	US
Kind code	B2
Filing date	May 22, 2024
Priority date	Aug 24, 2021
Publication date	Dec 23, 2025
Grant date	Dec 23, 2025

Abstract

A rail-based solar panel mounting system including at least one mounting bracket coupled to a mounting surface and at least one elongated rail having an open channel configuration, wherein the at least one elongated rail is coupled to the at least one mounting bracket. The mounting system also includes at least one mid-clamp assembly couplable to the at least one elongated rail, wherein the at least one mid-clamp assembly is configured to retain at least one solar panel relative to the at least one elongated rail.

First claim

The invention claimed is:

1 . A hidden end clamp assembly configured to secure a frame member of a solar panel module to a rail having an open portion and a top surface, the assembly comprising:
a clamping body, wherein the clamping body configured to be received within the open portion of the rail member wherein the clamping body, comprises
a top clamping portion having a lower clamping surface and a surface width,
a leg portion extending downwardly from the top clamping portion at an acute angle, wherein a distal end portion of the leg portion comprises a base portion having at least one elongated opening formed therethrough and a leg width;
a nut member, wherein the nut member comprises a pair of flanges extending upward from a central portion of the nut member, wherein the central portion at least partially contacts the leg portion of clamping body, and further wherein the central portion comprises a threaded opening formed therethrough; and
a fastener member, wherein the fastener member comprises a drive head and a threaded shank, and wherein the threaded shank is configured to extend through the at least one elongated opening of the base portion and engage with the threaded opening of the central portion of the nut member, such that tightening of the fastening member causes the lower clamping surface to move downward relative to the top surface of the rail and the base portion of the leg portion to move closer to the central portion;
wherein the surface width is larger than the leg width and the lower clamping surface overhangs the drive head.

2 . The assembly of claim 1 , wherein the top clamping portion further comprises one or more bonding portions extending from the lower clamping surface, wherein the bonding portions are formed of an electrically conducting material.

3 . The assembly of claim 2 , wherein the one or more bonding portions comprise one or more sharp piercing points.

4 . The assembly of claim 1 , wherein the base portion of the clamping body comprises at least one elongated opening having a pair of elongated openings formed therethrough.

5 . The assembly of claim 1 , further comprising a retaining member having an opening configured to be coupled to the clamping body and the nut member by the fastener member extending through the opening to support the clamping body relative to the nut member when the fastener member is in an untightened state.

6 . The assembly of claim 5 , wherein the retaining member comprises a bottom retaining portion, a front extension, a rear extension, and a curved portion coupling the front extension and the rear extension, wherein the rear extension is configured to extend within the central portion of the nut member such that the retaining member acts as a spring to urge the central portion of the nut member away from the leg portion of the clamping body.

7 . The assembly of claim 6 , wherein the front extension comprises a front through-hole and the rear extension comprises a rear through-hole, wherein the front through-hole and the rear-through hole are sized and configured to receive the threaded shank of the fastener member therethrough so as to couple the retaining member to the clamping body and the nut member.

8 . The assembly of claim 1 , wherein the base portion of the clamping body further comprises a pair of projecting side surfaces having respective sloping ledges and the flanges of the nut member comprise respective sloping flange bottom surfaces, further wherein the sloping flange bottom surfaces engage the sloping ledges when the fastening member is tightened.

9 . The assembly of claim 1 , wherein the pair of flanges of the nut member further comprise respective wing projections angled outwardly therefrom, wherein the wing projections are configured to provide a slidable interface between the nut member and a pair of elongated recesses of the rail.

10 . The assembly of claim 9 , wherein each wing projection comprises at least one piercing projection extending from an upper portion of a notch.

11 . The assembly of claim 1 , wherein the base portion of the clamping body further comprises a front face, wherein a surface plane of the front face is parallel to the angled leg portion of the clamping body.

12 . The assembly of claim 1 , wherein a rear surface of the top clamping portion of the clamping body comprises a plurality of parallel ribs to form a textured surface.

13 . The assembly of claim 1 , wherein the base portion of the clamping body further comprises a barb connector.

14 . The assembly of claim 13 , further comprising a tether, wherein the tether is configured to be coupled to the barb connector.

15 . The assembly of claim 14 , wherein the tether comprises a pulling end portion, an elongated central portion, and a coupling end portion, wherein the coupling end portion comprises an opening sized and configured to surround the barb connector.

16 . The assembly of claim 1 , wherein each of the clamp body, the nut member, and the fastener member are formed of an electrically conducting material.

17 . A hidden end clamp assembly configured to secure a solar panel module frame member having a lower flange to a rail having a top surface, the assembly comprising:
a clamping body, wherein the clamping body comprises a top clamping portion having a lower clamping surface and a leg portion extending downwardly below the lower clamping surface, wherein a lower portion of the leg portion comprises a base portion having at least one elongated opening formed therethrough; a nut member, wherein the nut member comprises a pair of flanges extending from a rear portion of the hidden end clamp assembly, wherein the pair of flanges are spaced apart so as to at least partially receive the leg portion of clamping body between the flanges, wherein the rear portion comprises a threaded opening formed therethrough; and a fastener member, comprises a drive head and a threaded shank, the threaded shank through the at least one elongated opening of the base portion and engages with the threaded opening of the rear portion of the nut member such that tightening of the fastener member causes the clamping body to secure a flange portion of the frame member between the lower clamping surface and the top surface; wherein the leg portion separates the drive head and the nut member and the pair of flanges are vertically located above the fastener member.

18 . The assembly of claim 17 , a retaining member positioned at least partially between the clamping body and the nut member and configured to support the clamping body relative to the nut member wherein the retaining member comprises a bottom retaining portion, a front extension, a rear extension, and a curved portion coupling the front extension and the rear extension, wherein the rear extension is configured to extend within the rear portion of the nut member such that the retaining member acts as a spring to urge the rear portion of the nut member away from the leg portion of the clamping body.

19 . The assembly of claim 17 , wherein the clamping body comprises a barb connector extending from a surface thereof; and a tether, wherein the tether is configured to be couplable to the barb connector of the base portion of the clamping body to allow the assembly to be selectively positioned along the rail such that the lower clamping portion of the clamping body extends at least partially over the solar panel module frame member.

20 . The assembly of claim 19 , wherein a longitudinal axis of the t

Assignees

• Ironridge Inc

Inventors

• Pedlar Roger
• Lester Bryan
• Justice Anumeha
• Menton Duane
• Greer Joe
• Parsley Alexander
• Wensley Jordan

Classifications

• F24S2025/6003

  by clamping · CPC title

• F24S25/35

  by means of profiles with a cross-section defining separate supporting portions for adjacent modules · CPC title

• F24S2025/6006

  by using threaded elements, e.g. stud bolts · 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

• F24S25/634

  Clamps; Clips · CPC title