End clamp for mounting solar module to rail

Patent metadata

Field	Value
Publication number	US-9813015-B1
Application number	US-201615196599-A
Country	US
Kind code	B1
Filing date	Jun 29, 2016
Priority date	Jun 29, 2016
Publication date	Nov 7, 2017
Grant date	Nov 7, 2017

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 frame of the solar module and the rail.

First claim

What is claimed is:

1. A solar power system comprising:
a rail having an end, an interior top surface, an interior bottom surface, and an exterior top surface;
a solar module disposed atop the exterior top surface of the rail; 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 disposed at least partially outside of the rail comprising a clamping plate wedge disposed inside the rail, wherein the clamping plate secures the solar module to the exterior top surface of the rail,
an inner wedge disposed inside the rail and coupled to the interior bottom surface,
a block disposed between and engaged with the clamping plate wedge and inner wedge, wherein

the tail end of the fastener is engaged with the inner wedge to apply a first force in a first horizontal direction on the inner wedge, wherein the head end of the fastener is engaged with the clamping plate to apply a second force in a second horizontal direction on the clamping plate, and wherein the inner wedge and clamping plate wedge impart a vertical force onto the block in a vertical direction to cause the block to engage with the interior top surface.

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

3. The solar power system of claim 1 wherein:
the solar module comprises a frame, and
at least a portion of the clamping plate is disposed atop the frame.

4. The solar power system of claim 1 wherein:
the solar module comprises a frame having an anodization layer, and the clamping plate further comprises one or more grounding teeth breaking the anodization layer.

5. The solar power system of claim 1 wherein
the clamping plate further comprises an anodization layer,
the fastener comprises one or more grounding teeth adapted to break the anodization layer.

6. The solar power system of claim 1 wherein the clamping plate further comprises one or more drainage features adapted to allow liquid to drain from the rail.

7. The solar power system of claim 1 wherein the clamping plate further comprises a recessed aperture, wherein the head end of the fastener is disposed within the recessed aperture.

8. The solar power system of claim 1 wherein the inner wedge comprises one or more points engaged with the interior bottom surface.

9. The solar power system of claim 1 wherein
the inner wedge comprises a threaded aperture, the fastener is at least partially threaded,
and at least some of the threads of the fastener are disposed within and engaged with the threaded aperture.

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

11. The solar power system of claim 10 wherein the electrical grounding path is established from the frame, through the clamping plate, through the fastener, through the inner wedge, to the rail.

12. The solar power system of claim 1 wherein the fastener and inner wedge comprise steel or stainless steel.

13. The solar power system of claim 1 wherein the clamping plate comprises one or more of aluminum, steel, stainless steel, polymer, or composite.

14. The solar power system of claim 1 :
wherein the block includes a first wedge surface and a second wedge surface;
wherein the clamping plate wedge and the first wedge are shaped to mate with and bear against one another; and
wherein the inner wedge and the second wedge surface are shaped to mate with and bear against one another.

15. A solar power system comprising:
a first rail having an end, an interior top surface, an interior bottom surface, and an exterior top surface;
a second rail having an end, an interior top surface, an interior bottom surface, and an exterior top surface;
a solar module disposed atop the first rail and the second rail; and
a first end clamp disposed at least partially inside the first rail at the end of the first rail and a second end clamp disposed at least partially inside the second rail at the end of the second rail, each of the first and second end clamps comprising:
a fastener having a head end and a tail end;
a clamping plate disposed at least partially outside of the rail comprising a clamping plate wedge disposed inside the rail, wherein the clamping plate secures the solar module to the exterior top surface of the rail,
an inner wedge disposed inside the rail coupled to the interior bottom surface,
a block disposed between and engaged with the clamping plate wedge and inner wedge,

wherein the tail end of the fastener is engaged with the inner wedge to apply a first force in a first horizontal direction on the inner wedge, wherein 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 wherein the inner wedge and clamping plate wedge cooperate to impart a vertical force onto the block in a vertical direction to cause the block to engage with the interior top surface.

16. 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 adapted to be disposed at least partially outside of the rail comprising a clamping plate wedge adapted to be disposed inside the rail, wherein the clamping plate is adapted to secure a module to the top of the rail,
an inner wedge adapted to be disposed inside the rail and coupled to the interior bottom surface,
a block disposed between and engaged with the clamping plate wedge and inner wedge, wherein

the tail end of the fastener is engaged with the inner wedge to apply a first force in a first horizontal direction on the inner wedge, 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 wedge and clamping plate wedge deflect the first force and second force onto the block in the vertical direction causing the block to engage with the interior top surface.

17. The mounting system of claim 16 wherein
the clamping plate further comprises an anodization layer,
the fastener comprises one or more grounding teeth adapted to break the anodization layer.

18. The mounting system of claim 16 wherein the clamping plate further comprises a recessed aperture, wherein the head end of the fastener is disposed within the recessed aperture.

19. The mounting system of claim 16 wherein
the inner wedge comprises a threaded aperture, the fastener is at least partially threaded, and
at least some of the threads of the fastener are disposed within and engaged with the threaded aperture.

20. The mounting system of claim 16 :
wherein the block includes a first wedge surface and a second wedge surface;
wherein the clamping plate wedge and the first wedge are shaped to mate with and bear against one another; and
wherein the inner wedge and the second wedge surface are shaped to mate with and bear against one another.

Assignees

• Sunpower Corp

Inventors

• Kapla John Paul
• Feldmann Kyle Donald
• Benjamin Dylan

Classifications

• H02S20/23 Primary

  specially adapted for roof structures · CPC title

• B25B5/145

  for plates · CPC title

• B25B5/163

  Jaws or jaw attachments · CPC title

• H02S30/10

  Frame structures · CPC title

• Y02E10/47

  Mountings or tracking · CPC title