CN116420307A - Spring clamp for photovoltaic module installation - Google Patents

Abstract

The module mounting system may include a Photovoltaic (PV) module frame including mounting rails. The module mounting system may include a spring clip having a photovoltaic module frame engagement element and a clip engagement element. The spring clip may apply a spring force through deformation to lock the photovoltaic module frame and clip together. The second embodiment of the spring clip may include an upper member having one or more arms and a lower member having a central ring, the upper and lower members being configured to rotate relative to one another and engage a photovoltaic module frame or mounting rail. A second embodiment of the module mounting system may include a threadless clamp comprising an outer wall and an inner wall coupled together as a continuous sheet of material. The threadless clamps may be coupled to the respective mounting flanges and the respective frame flanges to lock the mounting purlins and the photovoltaic module frame together.

Description

Spring clamp for photovoltaic module installation

Cross Reference to Related Applications

The present application claims priority and benefit from U.S. utility patent application Ser. No. 17/474,607 entitled "spring clip for photovoltaic module installation (" SPRING CLIP FOR PHOTOVOLTAIC MODULE MOUNTING "), U.S. provisional application Ser. No. 63/195,629 entitled" screwless clip for photovoltaic module ("SCREWLESS CLIP FOR PHOTOVOLTAIC MODULE"), and U.S. provisional application Ser. No. 63/078,177 entitled "spring clip for photovoltaic module installation (" SPRING CLIP FOR PHOTOVOLTAIC MODULE MOUNTING ") by 14, 9, 2020, filed on by 2021, and each incorporated herein by reference in its entirety.

Technical Field

The present disclosure relates generally to spring clips for photovoltaic ("PV") module mounting.

Background

Most photovoltaic modules are heavy because they use glass to encase the photovoltaic cells. Thus, the solar tracking system must be able to withstand the weight of one or more photovoltaic module arrays and the natural forces that may act thereon. In addition to supporting a heavy solar cell array and the associated natural forces, the solar tracking apparatus must also be able to move the solar cell array so that it tracks the sun. The photovoltaic modules and their associated frames must be mounted to the support structure of the solar cell array and the solar tracking apparatus. However, there is a need for improved mounting methods.

The subject matter claimed in this disclosure is not limited to embodiments that solve any disadvantages, nor to embodiments that operate only in the environments described above. Rather, this background is provided to illustrate one example technical area in which some embodiments described in this disclosure may be implemented.

Disclosure of Invention

One or more embodiments of the present disclosure may include a module mounting system including a Photovoltaic (PV) module frame surrounding one or more photovoltaic cells. The module mounting system may also include a mounting rail configured to engage the photovoltaic module frame, and one or more support structures to which the mounting rail is coupled to hold the mounting rail off the ground. The module mounting system may further include a spring clip having a photovoltaic module frame engagement section and a mounting rail engagement section, wherein the spring clip is shaped to apply a spring force by deformation of the spring clip to urge the mounting rail and the photovoltaic module frame against each other.

One or more embodiments of the present disclosure can include a spring clip including an upper member having one or more arms. The spring clip may further comprise a lower part comprising a central ring, wherein the upper part and the lower part are configured to rotate relative to each other about a hinge point to transition from an initial position to a final position, wherein the final position results in the arms of the upper part engaging with the photovoltaic module frame, and the central ring of the lower part engaging with the mounting rail to force the mounting rail and the photovoltaic module frame against each other.

One or more embodiments of the present disclosure may include a module mounting system including a mounting purlin including one or more mounting flanges extending horizontally from the mounting purlin, and a photovoltaic module frame including one or more frame flanges extending horizontally from the photovoltaic module frame, wherein each frame flange may be abuttingly engaged with a corresponding mounting flange of the mounting purlin. The module mounting system may further include one or more threadless clips engaged with the mounting flange and the frame flange, wherein each threadless clip includes one or more outer walls and one or more inner walls formed from a continuous sheet of material in a generally W-shaped profile.

The objects and advantages of the embodiments will be realized and attained by means of the elements, features, and combinations particularly pointed out in the appended claims. It is to be understood that both the foregoing general description and the following detailed description are explanatory only and are not restrictive of the invention as claimed.

Drawings

To further clarify the above and other advantages and features of the present invention, a more particular description of the invention will be rendered by reference to specific embodiments thereof which are illustrated in the appended drawings. It is appreciated that these drawings depict only typical embodiments of the disclosure and are therefore not to be considered limiting of its scope. The present disclosure will be described and explained with additional specificity and detail through the use of the accompanying drawings in which:

FIGS. 1A-1D illustrate an exemplary embodiment of a module mounting system with a spring clip according to the present disclosure;

2A-2D illustrate another exemplary embodiment of a module mounting system with a spring clip according to the present disclosure;

3A-3E illustrate yet another exemplary embodiment of a module mounting system with a spring clip according to the present disclosure;

FIG. 3F illustrates another exemplary embodiment of a module mounting system with a spring clip according to the present disclosure;

Fig. 4A illustrates a first exemplary embodiment of a first threadless clamp for fastening a photovoltaic module frame according to the present disclosure;

fig. 4B illustrates an exemplary embodiment of a second threadless clamp for fastening a photovoltaic module frame according to the present disclosure;

FIG. 5A illustrates a first exemplary embodiment of a first mounting purlin in accordance with the disclosure;

FIG. 5B illustrates a second exemplary embodiment of a second mounting purlin according to the disclosure;

FIG. 6A illustrates a view of an exemplary embodiment of a first mounting assembly including a first threadless clip and a first mounting purlin coupled to a photovoltaic module frame according to the present disclosure;

FIG. 6B illustrates a second view of the exemplary embodiment of the first mounting assembly illustrated in FIG. 6A in accordance with the present disclosure;

FIG. 6C illustrates a side view of the exemplary embodiment of the first mounting assembly illustrated in FIG. 6A according to the present disclosure;

FIG. 6D illustrates a front view of the exemplary embodiment of the first mounting assembly illustrated in FIG. 6A in accordance with the present disclosure;

FIG. 6E illustrates a view of an exemplary embodiment of a second mounting assembly according to the present disclosure including the second threadless clip shown in FIG. 4B and the second mounting purlin shown in FIG. 5B coupled to a photovoltaic module frame;

FIG. 7A illustrates an exemplary embodiment of a third threadless clamp according to the present disclosure;

FIG. 7B illustrates an exemplary embodiment of a fourth threadless clamp according to the disclosure; and

fig. 7C illustrates an exemplary embodiment of a fifth threadless clamp according to the disclosure.

Detailed Description

The present disclosure relates to improvements in mounting methods for mounting photovoltaic modules and their associated frames to a support structure of a photovoltaic module array. For example, an array of photovoltaic modules may be mounted to a torque tube that facilitates tracking the sun with the photovoltaic modules. In the present disclosure, the module mounting system may include a photovoltaic module frame for holding the photovoltaic module itself, as well as mounting rails fixedly coupled to a torque tube or other support structure of the photovoltaic module array. In accordance with the present disclosure, the spring clip is operable to lock the photovoltaic module frame relative to the mounting rail. The spring clip may provide a means to generate and apply a spring force to the photovoltaic module frame and the mounting rail due to deformation of the spring clip, thereby locking them in place relative to each other. In this disclosure, various embodiments of the form factor of the spring clip are contemplated.

By using a spring clip according to at least some embodiments of the present disclosure, a tool-less installation method may be employed. For example, instead of maintaining and retaining a large number of pneumatic drives, battery operated drills, and calibrated torque wrenches, these tools are capable of driving bolts or other connection devices to a specified torque and having appropriate quality control functions to verify such machines, tool-free installations can avoid all of these costs and burdens. For threaded fasteners, the clamping force is achieved by applying torque to the fastener, which can inherently vary based on the condition of the threads, tools, etc., in uncontrolled outdoor environments. Instead, any constraints or concerns may be placed on the proper force loading, etc. during quality control of the manufacturing process and/or design of the spring clip itself, as it is easier to control during these processes. The spring clips may be designed to lock the mounting rail and the photovoltaic module frame together even when they are exposed to the expected forces, such as wind, snow, rain, sun tracking, etc. Furthermore, the spring clip may be designed for manual installation, or with the aid of a simple off-the-shelf tool (e.g., a crowbar or crowbar). While the use of custom tools is within the scope of the present disclosure, depending on the design of the spring clip, the use of such tools may or may not be required.

The present disclosure also relates to clamps that may be used to couple a photovoltaic frame to a mounting rail or other structure (e.g., a mounting purlin). The clip may include features that bite into either or both of the photovoltaic frame and the mounting structure to help lock the two components together and/or to help electrically couple the two together to provide grounding of the photovoltaic frame to the mounting structure. In some embodiments, one or both structures coupled together may include a gap or hole into which a tooth or locking lip may extend to lock the clamp in place and/or lock the photovoltaic frame and mounting structure together.

In the following paragraphs, embodiments will be described in detail by way of example with reference to the accompanying drawings, which may or may not be drawn to scale, and the illustrated components are not necessarily drawn to scale with each other. Throughout the description, the embodiments and examples shown should be considered as exemplars, rather than limitations on the present disclosure. As used herein, "the present disclosure" refers to any one of the embodiments described herein, as well as any equivalents. Furthermore, references herein to various aspects of the disclosure are not intended to imply that all of the claimed embodiments or methods must include the referenced aspects.

Fig. 1A-1D illustrate an exemplary embodiment of a module mounting system 100 having a spring clip 110 according to the present disclosure. The module mounting system 100 may include a photovoltaic module frame 150 for holding the photovoltaic modules themselves, and a mounting rail 160 fixedly coupled to a torque tube or other support structure of the photovoltaic module array. The spring clips 110 are operable to lock the photovoltaic module frame 150 relative to the mounting rails 160.

The spring clip 110 may include one or more photovoltaic module engagement sections, such as wings 112, for engagement with the flange 152 of the photovoltaic module frame 150. The wings 112 may be spaced apart such that one wing 112b of the spring clip 110 (as shown in fig. 1A) may slide over one flange 152b and still have room for the other wing 112a to slide over the other flange 152 a. Once slid over the other flange 152a, the spring clip 110 may be centered between the two flanges 152 such that both wings 112 engage the flanges 152.

As shown in fig. 1C, after being mounted on the flange 152 of the photovoltaic module frame 150, the spring clip 110 may slide toward the mounting rail 160. The mounting rail 160 may include a locking ramp 162 formed in a surface of the mounting rail opposite the surface that engages the photovoltaic module frame 150. Spring clip 110 may include a mounting rail engagement section, such as a centering ring 114, sized to correspond with locking ramp 162. As the spring clip 110 slides along the length of the photovoltaic module frame 150 toward the final position of the spring clip 110, the center ring 114 of the spring clip 110 may engage the locking ramp 162 and then be forced up and over the locking ramp 162, as shown in fig. 1D.

In some embodiments, the locking ramp 162 may have features, shapes, protrusions, etc. to prevent the spring clamp 110 from moving back up past the locking ramp 162. For example, the locking ramp 162 may have a profile similar to a shark fin.

In some embodiments, the spring clip 110 may be designed and shaped such that an amount of force is applied to each flange 152 and mounting rail 160 of the photovoltaic module frame 150, effectively clamping the photovoltaic module frame 150 and mounting rail 160 together. In these and other embodiments, the applicable force may be determined when spring clamp 110 is in the position shown in FIG. 1D. The spring clip 110 may be designed to provide a sufficient spring force to hold the photovoltaic module frame 150 and the mounting rail 160 locked in place relative to one another upon encountering a known force applied to the photovoltaic module frame 150 and the mounting rail 160. These forces may include the weight of the photovoltaic module itself, forces due to rotating torque tubes while tracking the sun, forces due to wind, rain, snow, etc., or any other forces that the photovoltaic module frame 150 and mounting rail 160 are known to withstand.

In some embodiments, the spring clip 110 may apply a force to the photovoltaic module frame 150 and the mounting rail 160 even before being forced up and over the locking ramp 162. For example, the centering ring 114 may be positioned such that when the spring clamp 110 is in the passive form, the centering ring 114 is closer to the photovoltaic module frame 150 than the surface of the mounting rail 160 such that the spring clamp 110 deforms a first amount to cause the centering ring to reach the surface of the mounting rail 160. As the spring clamp 110 slides up the locking ramp 162 and over the locking ramp 162, the spring clamp 110 may be in a further amount of deformation and may return to about the first amount of deformation after descending past the locking ramp 162.

Although an example of a single spring clip 110 is shown, it should be understood that multiple spring clips 110 may be used to couple the photovoltaic module frame 150 with the mounting rail 160.

Fig. 2A-2D illustrate another exemplary embodiment of a module mounting system 200 having a spring clip 210 according to one or more embodiments of the present disclosure. The module mounting system 200 may include like numbered components and elements as shown in fig. 1A-1D, such as a photovoltaic module frame 250, which may be similar or comparable to the photovoltaic module frame 150, and a mounting rail 260, which may be similar or comparable to the mounting rail 160. Fig. 2A shows a perspective view of the spring clip 210 locked in place, as also shown in fig. 2D.

As shown in fig. 2A-2D, the mounting rail 260 may include a slot 262 in which the spring clip 210 may reside. For example, during manufacturing, the spring clip 210 may be at least partially formed in the groove 262 such that the spring clip 210 is trapped in the groove 262. In this manner, the installer need not be aware or care about separately carrying the spring clip 210 when shipping and/or arranging for installation, as it will be located within the slot 262.

The spring clip 210 may be shaped with an arm 212, the arm 212 configured to protrude upward into a hole in the flange of the photovoltaic module frame 250 that is positioned to correspond to the slot 262 and the spring clip 210. For example, as shown in fig. 2B, the photovoltaic module frame 250 may be positioned on top of the mounting rail 260 such that the arms 212 of the spring clip 210 can protrude upward into the holes.

As shown in the transition of fig. 2B to fig. 2C and 2D, the spring clip 210 may be pushed back along the slot 262 and transition from the initial position shown in fig. 2B to the final position shown in fig. 2D by rotating about the base of the arm 212. In some embodiments, the bending of the spring clip 210 near the angle of the arm 212 provides a spring force to lock the photovoltaic module frame 250 and the mounting rail 260 together.

As shown in fig. 2D, in some embodiments, the slot 262 may include a locking ramp 263 such that when the spring clamp 210 is pushed upward and beyond the locking ramp 263 toward the final position of the spring clamp 210, the spring clamp 210 may fall into an end of the slot 262 on the other side of the locking ramp 263 to lock the spring clamp 210 in place (e.g., after reaching the final position of the spring clamp 210). In these and other embodiments, the spring clip 210 and/or the groove 262 can be designed such that when in the position shown in fig. 2D, the spring force of the spring clip 210 is sufficient to relatively lock the mounting rail 260 and the photovoltaic module frame 250 even when a desired force (e.g., a force due to wind, rain, sun tracking, etc.) is encountered.

In some embodiments, the slots 262 may extend to the edges of the mounting rail 260 such that the edges are open. In these and other embodiments, the spring clip 210 may be manufactured and/or transported separately from the mounting rail 260. Spring clip 210 may be loaded into slot 262 and arm 212 may then be inserted into a hole in photovoltaic module frame 250 and pushed back over locking ramp 263 to lock spring clip 210 in place. In these and other embodiments, a locking device (not shown) may be placed in the edge of the mounting rail 260 and/or the slot 262 to prevent the spring clip 210 from rotating back up and over the locking ramp 263 or out of the slot 262.

Fig. 3A-3F illustrate another exemplary embodiment of a component mounting system 300 having a spring clip 310 according to the present disclosure. The assembly mounting system 300 may include similarly numbered components and elements as shown in fig. 1A-1D and/or fig. 2A-2D, such as a photovoltaic module frame 350, which may be similar or comparable to the photovoltaic module frames 150 and/or 250, and a mounting rail 360, which may be similar or comparable to the mounting rails 160 and/or 260. The spring clip 310 may operate in a manner similar to a spring-top bottle to lock the photovoltaic module frame 350 and the mounting rail 360 together.

Spring clip 310 may include an upper member having arms 312 and a lower member having a center ring 314. The upper and lower sections may include hinge points 316 (e.g., hinge points 316a and 316b on each side of the spring clip as shown in fig. 3D) about which the upper and lower members rotate relative to each other. For example, the upper component may include a post that extends through a hole in the lower component to form the hinge point 316, although any configuration that allows the two components to rotate relative to one another is within the scope of the disclosure (e.g., the lower component may include a post, and the upper component may include a hole, etc.).

In some embodiments, the ends of the lower member may extend through holes in the mounting rail 360 to form pivot points 318 (e.g., pivot points 318a and 318b on either side of the spring clip 310) about which the entire spring clip 310 may rotate relative to the mounting rail 360. By using a combination of hinge point 316 and pivot point 318, the spring clip may be able to rotate back and lock into place, as observed in the transition from fig. 3A to 3B to 3C. For example, the centering ring 314 may be rotated downward and around the end of the mounting rail 360 until the centering ring 314 abuts a bottom surface of the mounting rail 360 (e.g., a surface on the opposite side of the photovoltaic module frame 350). As another example, the arm 312b of the upper member as shown in fig. 3E may extend upward as the lower member rotates such that the arm 312b extends through corresponding holes in the mounting rail 360 and/or the photovoltaic module frame 350.

When moving from an initial open position (e.g., as shown in fig. 3A) to a final locked position (e.g., as shown in fig. 3C), hinge point 316 may move from one side of pivot point 318 to the other. By doing so, the arm 312 may prevent and/or inhibit movement of the upper component, and since the hinge point 316 and pivot point 318 are vertically aligned, the greatest compressive force is applied to the photovoltaic module frame 350 and the mounting rail 360. As hinge point 316 moves past pivot point 318, the physical force tends to force center ring 314 against mounting rail 360 as the physical force attempts to rotate hinge point 316 further past pivot point 318 to reduce the compressive force.

In some embodiments, the mounting rail 360 may be manufactured and/or transported for mounting with the spring clip 310, which spring clip 310 already has a post passing through a hole at the pivot point 318. During installation, the photovoltaic module frame 350 may be moved laterally relative to the mounting rail 360 until the aperture corresponding to the arm 312 may be in place so that the arm 312 may be guided up through the aperture. In some embodiments, such guiding may utilize movement of the photovoltaic module frame 350 relative to the mounting rail 360. The holes for the arms 312 in the photovoltaic module frame 350 may be similar or comparable to the holes described with reference to fig. 2A-2D.

In these and other embodiments, the spring clip 310 can be designed such that when in a locked position (e.g., as shown in fig. 3C), the spring clip 310 can apply sufficient force to lock the photovoltaic module frame 350 relative to the mounting rail 360 when exposed to the expected force.

In some embodiments, the mounting rail 360 may include a locking ramp (not shown) along a bottom surface of the mounting rail 360. The locking ramp may include features that prevent the center ring 314 from rotating back over the locking ramp as the center ring 314 travels up and over the locking ramp and past the locking ramp. For example, the locking ramps may include a shape or profile similar to that shown for locking ramps 162 and 263 in fig. 1C and/or fig. 2D, respectively.

As shown in fig. 3F, in some embodiments, spring clip 311 (which may be similar or comparable to spring clip 310) may include arm 313 (e.g., arms 313a/313 b) instead of arm 312. For example, the arms 313a and 313b may be positioned to rotate upward and around the exterior of the photovoltaic module frame 350 such that the arms 313a/313b may press against the top surface of the photovoltaic module frame 350 instead of protruding upward and through the photovoltaic module frame 350 as the arms 312 do. After rotating upward and with the top of the photovoltaic module frame 350 in place, the centering ring 314 may be rotated to a locked position in a manner similar or equivalent to that described with reference to fig. 3A-3E.

Any of fig. 1A-3F of the present disclosure may be modified, added, or omitted. For example, variations as described herein may be made based on knowledge of one of ordinary skill in the art. For example, the mounting rail and/or photovoltaic frame may take any form or shape, and the shape of the spring clip may be adjusted to accommodate any such variations.

In some embodiments, the spring clip of various embodiments of the present disclosure may be formed from a single piece of metal rod that may be formed, shaped, bent, etc. to have the form shown in fig. 1A-3F. Additionally or alternatively, the spring clips may be bonded or coupled together by multiple segments of metal to form the form shown in fig. 1A-3F. In some embodiments, portions of the spring clip may be pressed, stamped or otherwise formed to have a flat surface instead of a rounded surface, such as the surface of a wing and/or center ring that engages a flange and/or mounting rail, respectively.

Fig. 4A illustrates a first exemplary embodiment of a first threadless clamp 400a for fastening a photovoltaic module frame according to the present disclosure. The threadless clamp 400a may include one or more outer walls 410a and one or more inner walls 420. In some embodiments, the threadless clamp 400a may include two outer walls 410a and two inner walls 420 such that the threadless clamp includes a W-shaped profile. In some embodiments, the outer wall 410a and the inner wall 420 may be formed from one or more continuous pieces of material, such as metal. For example, the threadless clamp 400a may be formed by roll forming two or more sheets, molding, casting, welding together, or the like. In some embodiments, the threadless clip 400a can be shaped to include inherent structural strength in the vertical direction, which can prevent the photovoltaic module frame and/or mounting purlin from separating under load. Accordingly, the inner wall 420 may include a greater height than the outer wall 410 a. In these and other embodiments, the threadless clamp 400a may be formed from steel and/or by a roll forming process using materials such as extruded aluminum, cast iron, stainless steel, high density polyethylene, polyvinyl chloride, and the like. In some embodiments, the threadless clamp 400a may be formed of a conductive material.

The outer wall 410a may include a locking tab 440 and/or a locking recess 442a. In some embodiments, locking tabs 440 and/or locking recesses 442a may engage with surfaces corresponding to mounting purlins and/or flanges of a photovoltaic module frame to facilitate fastening the photovoltaic module frame to the mounting purlins. In some embodiments, the outer wall 410a may include locking tabs 440 on one or more edges of the outer wall 410a such that the locking tabs 440 of the outer wall 410a are oriented in an upward direction. In some embodiments, the outer wall 410a may include a locking recess 442a on an edge of the outer wall 410a adjacent to the locking tab 440. In these and other embodiments, the locking recess 442a may be positioned behind the locking tab 440 along the same edge as the locking tab 440 such that the locking recess 442a is positioned closer to the center of the edge of the outer wall 410a than the locking tab 440. Additionally or alternatively, the inner wall 420 may include grounding teeth 430, the grounding teeth 430 being configured to engage with a surface of a mounting purlin and/or a photovoltaic module frame.

In some embodiments, slot openings 425 may be included in one or more of the inner walls 420, and grounding teeth 430 may be formed along a top edge of the slot openings 425. The width of the slot opening 425 may be less than the thickness of the mounting flange of the mounting purlin coupled to the threadless clamp 400a and/or the thickness of the frame flange of the photovoltaic module frame such that the threadless clamp 400a applies a predetermined amount of clamping force to the mounting purlin and/or the flange of the photovoltaic module frame. In some embodiments, locking tabs 440 may engage with adjoining holes in the photovoltaic module frame and/or mounting purlins to reduce and/or prevent relative sliding movement between the photovoltaic module frame and the mounting purlins.

In some embodiments, the grounding teeth 430 and/or teeth on the locking tabs 440 may cooperate to provide a damping force corresponding to the threadless clip 400a being removed after being slid into place to couple the mounting purlin and/or surface of the photovoltaic module frame. For example, the teeth on the grounding teeth 430 and/or locking tabs 440 may be oriented toward the back of the slot openings 425 so that the teeth on the grounding teeth 430 and/or locking tabs 440 may bite deeper into the material to act as barbs when a force is applied to pull the threadless clip 400a away from the surface of the mounting purlin and/or photovoltaic module frame.

Fig. 4B illustrates a second exemplary embodiment of a second threadless clamp 400B for securing a photovoltaic module frame according to the present disclosure. In some embodiments, the threadless clamp 400b may include the same or similar inner walls as the inner wall 420 of the threadless clamp 400a, i.e., a groove may be included in a surface of each inner wall, and ground engaging teeth may be included along a top edge of the groove. Additionally or alternatively, the threadless clamp 400b may include semi-circular locking recesses 442b along one or more outer walls 410b of the threadless clamp 400b without including locking tabs along a top edge of the outer walls 410 b. Although illustrated as semi-circular, the locking recess 442b may take any shape (e.g., rectangular, rounded rectangular, etc.).

Fig. 5A illustrates a perspective view of a first exemplary embodiment of a first mounting purlin 500a in accordance with the disclosure. The first mounting purlin 500a shown in fig. 5A may include a short cross-sectional view of the mounting purlin, and the length of the first mounting purlin 500a may vary depending on the length of the photovoltaic module coupled to the first mounting purlin 500 a. For example, the first mounting purlin 500a may include a longer length to accommodate a longer photovoltaic module length (or a shorter length to accommodate a shorter photovoltaic module length). In some embodiments, the mounting purlin 500a may include a base portion 510, one or more mounting flanges 520a, and/or one or more mounting slots 530. In these and other embodiments, the mounting purlin 500a may include any shape, such as circular, triangular, orifice, etc.

The mounting flange 520a and/or the mounting groove 530 may extend laterally from the top of the base portion 510 (e.g., from the "edge" of the top-hat mounting purlin 500 a). In some embodiments, the mounting flange 520a may be flat or substantially flat such that the flange of the photovoltaic module frame may be positioned flush with the mounting flange 520 a. Additionally or alternatively, non-threaded clamps, such as non-threaded clamps 400a and/or 400b (collectively, "non-threaded clamps 400"), may be engaged with the mounting purlin 500a via the mounting flange 520b and/or the mounting groove 530. In some embodiments, the mounting slots 530 may provide openings through which the grounding teeth and/or locking tabs 440 of the threadless clip 400 may extend to secure the threadless clip 400 to the mounting purlin 500a and/or reduce and/or prevent sliding movement of the threadless clip 400 and/or the photovoltaic module frame.

Fig. 5B illustrates an exemplary embodiment of a second mounting purlin 500B in accordance with the disclosure. In some embodiments, the second mounting purlin 500b may include one or more mounting flanges 520b, and each mounting flange 520b may include an edge lip 535 along a portion or the entire edge of one or both mounting flanges 520 b. In these and other embodiments, the edge lip 535 may be configured to engage with the locking recess 442B of the threadless clamp 400B described with respect to fig. 4B. For example, one of the mounting flanges 520b may extend into a groove of the threadless clamp 400b and the edge lip 535 may engage with a locking recess 442b in an outer wall of the threadless clamp 400b to reduce and/or prevent sliding movement of the threadless clamp 400b and/or an associated photovoltaic module frame. For example, engagement of the edge lip 535 with the locking recess 442b may prevent any backing out and/or other removal of the threadless clamp 400 b.

Fig. 6A shows a view of an exemplary embodiment of a first mounting assembly 600a according to the present disclosure, the first mounting assembly 600a including a threadless clip 400a and a mounting purlin 500a coupled to a photovoltaic module frame 610. The photovoltaic module frame 610 may include one or more frame flanges 620, the frame flanges 620 being flat or substantially flat and may be positioned flush against the top surface of the mounting flange of the mounting purlin 500a. Although the mounting flange and the frame flange 620 are shown in fig. 6A as having the same shape and surface area, some offset in alignment between the mounting flange and the frame flange 620 is tolerated and is contemplated in the present disclosure. Additionally or alternatively, although the mounting flange and the frame flange 620 are shown in fig. 6A as having the same thickness, some differences in flange thickness may be tolerated. In these and other embodiments, the threadless clamp 400a may comprise different configurations, wherein the slot openings 425 of the threadless clamp 400a comprise different lengths, widths, and/or heights to accommodate mounting flanges 520 and/or frame flanges 620 of different thicknesses and/or lengths.

In some embodiments, the threadless clip 400a can be coupled to the mounting assembly 600a such that the upwardly oriented locking tabs 440 of the threadless clip 400a engage the bottom surface of the frame flange 620 of the photovoltaic module frame 610 through the slots in the mounting purlins 500a and the downwardly oriented grounding teeth 430 of the threadless clip 400a engage the top surface of the frame flange 620 of the photovoltaic module frame 610. The locking tabs 440 engaged with the bottom surface of the frame flange 620 and/or the grounding teeth 430 engaged with the top surface of the frame flange 620 may increase the clamping force exerted by the screwless clip 400a on the frame flange 620 of the photovoltaic module frame 610 and/or the flange of the mounting purlin 500a, thereby reducing and/or preventing relative sliding between the photovoltaic module frame 610 and the mounting purlin 500 a. Additionally or alternatively, the frame flange 620 may include slots corresponding to the slots in which the purlines 500a are installed.

Although illustrated as an example of a single threadless clip 400a, it should be appreciated that a plurality of threadless clips 400a may be used to couple the photovoltaic module frame 610 with the mounting purlin 500 a.

Fig. 6B illustrates a second assembly view of an exemplary embodiment of a first mounting assembly 600a according to the present disclosure. As shown in fig. 6B, the locking tab of the threadless clip 400a may extend through the slot of the mounting purlin 500a and engage the bottom surface of the frame flange 620 of the photovoltaic module frame 610.

Fig. 6C illustrates a side view of an exemplary embodiment of a first mounting assembly 600a according to the present disclosure. As shown in the side view of the mounting assembly 600a, the grounding teeth 430 and/or locking tabs 440 may engage the top and/or bottom surfaces, respectively, of the frame flange 620 of a photovoltaic module frame (not shown).

In some embodiments, the photovoltaic module frame may include a thin layer of anodized aluminum, which is typically electrically insulating. In these and other embodiments, the thickness of the anodized aluminum layer may range from one micron to ten microns. To facilitate grounding of the photovoltaic module through the mounting purlin, the grounding teeth 430 may cut into the anodized aluminum layer such that the threadless clamp 400a is in direct contact with the conductive material below the anodized aluminum layer. In these and other embodiments, the threadless clip 400a can facilitate grounding a given photovoltaic module through a photovoltaic module frame to which the given photovoltaic module is attached by providing a low resistance grounding path through the mounting purlin.

Fig. 6D illustrates a front view of an exemplary embodiment of a first mounting assembly 600a according to the present disclosure. In some embodiments, the shape of the threadless clip 400 may facilitate secure attachment of the threadless clip 400 to a mounting purlin and/or photovoltaic module frame. The longer inner wall 420 of the threadless gripper 400 may provide structural strength to the threadless gripper 400 in the vertical direction, which may prevent the photovoltaic module frame and/or mounting purlin from separating under load. Additionally or alternatively, the shorter outer wall 410 of the threadless clamp 400 may provide opposing spring forces that reduce and/or dissipate rattle, vibration, sliding, etc. of the threadless clamp 400 during operation of the photovoltaic module.

Fig. 6E illustrates an isometric view of an exemplary embodiment of a second mounting assembly 600b according to the present disclosure, the second mounting assembly 600b including a threadless clip 400b and a mounting purlin 500b coupled to a photovoltaic module frame 610. The top edge of the outer wall of the threadless clip 400b may engage the bottom surface of the mounting flange of the mounting purlin 500b and the grounding teeth of the threadless clip 400b may engage the top surface of the frame flange 620 of the photovoltaic module frame 610. Edge flanges 535 at the mounting flange ends of the mounting purlins 500b may engage with the locking recesses 442b to reduce and/or prevent sliding movement of the threadless clip 400b, the mounting purlins 500b, and/or the photovoltaic module frame 610.

Fig. 7A-7C illustrate various exemplary embodiments of a threadless clamp 700a-C according to this disclosure. In some embodiments, as shown in fig. 7A, the threadless clamp 700a may include one or more outer walls 710a connected to one or more inner walls 720a, wherein the angle of curvature between the outer walls 710a and the inner walls 720a is greater than the angle of curvature between the two inner walls 720 a. In other words, the gap between the tops of the two inner walls 720a may be wider than the gap between the bottoms of the two inner walls 720 a. The bending angle between two given walls can adjust the compressive force between the mounting flange of the mounting purlin and the frame flange of the photovoltaic module frame. For example, a greater angle of bending between the inner wall 720a of the threadless clip 700a may reduce contact between the upwardly facing edge of the outer wall 710a and the bottom surface of the mounting flange and/or the bottom surface of the frame flange (e.g., contact between the locking tab 440 and the bottom surface of the frame flange through the mounting groove), which may reduce compressive forces between the mounting purlin and the photovoltaic module frame. As another example, a narrower bend angle between the inner walls 720a may increase contact between the upwardly facing edge of the outer wall 710a and the bottom surface of the mounting flange and/or the frame flange, which may increase the compressive force between the mounting purlin and the photovoltaic module frame.

In some embodiments, the threadless clamp 700B, as shown in fig. 7B, may include one or more outer walls 710B, each outer wall including a truncated portion 715B. Removing a portion of the outer wall 710b beyond the truncated portion 715b may increase the resiliency of the outer wall 710b relative to longer outer walls (e.g., outer wall 410, outer wall 710a, and/or outer wall 710 c). In these and other embodiments, the inner wall 720b of the threadless clamp 700b may include one or more chamfers 725b that reduce the sharpness of the edges of the inner wall 720b, such that installation of the threadless clamp 700b may be easier and/or less dangerous to an installation technician (e.g., manually inserting the threadless clamp 700 b).

In some embodiments, the outer walls 710C of the threadless clamp 700C may each include a cut-out portion 715C, as shown in fig. 7C. For example, the threadless clamp 700c may include a cut-out portion 715c at a transition between the outer wall and the inner wall, with material connecting the outer wall and the inner wall at both ends of the cut-out portion 715 c. The cut-out portions 715c may provide clearance for pressing the inner walls 720c of the screwless clamp 700c together (e.g., by hand, using pliers, etc.), which may facilitate easier mounting of the screwless clamp 700c on the mounting flange and/or frame flange.

For example, the subject technology of the present disclosure is illustrated in accordance with various aspects of the following description. For convenience, various examples of aspects of the subject technology are described as numbered examples (1, 2, 3, etc.). These are provided as examples and do not limit the subject technology. It should be noted that any of the subordinate examples, or portions thereof, may be combined in any combination and placed in independent examples, such as examples 1, 2, and 3. Other examples may be presented in a similar manner. The following is a non-limiting summary of some examples given herein.

Example 1 includes a module mounting system, which may include a Photovoltaic (PV) module frame surrounding one or more photovoltaic cells. The module mounting system may include a mounting rail configured to engage with the photovoltaic module frame and one or more support structures to which the mounting rail is coupled to hold the mounting rail off the ground. The module mounting system may include a spring clip having a photovoltaic module frame engagement section and a mounting rail engagement portion, wherein the spring clip is shaped to apply a spring force through deformation of the spring clip to urge the mounting rail and the photovoltaic module frame against each other.

In some examples, the module mounting system may further include a second photovoltaic module frame adjacent to the photovoltaic module frame. The photovoltaic module frame and the second photovoltaic module frame may include first and second flanges, respectively, and the first and second flanges may extend in opposite directions and each engage a top surface of the mounting rail. The photovoltaic module frame engagement section of the spring clip may include at least a first wing and a second wing, wherein the first wing is configured to slide over the first flange and the second wing is configured to slide over the second flange such that the first wing engages a top surface of the first flange and the second wing engages a top surface of the second flange to secure both the photovoltaic module frame and the second photovoltaic module frame in place relative to the mounting rail.

In some examples, the photovoltaic module frame may include a locking ramp formed in a bottom surface of the mounting rail, and the mounting rail engagement portion of the spring clip may include a centering ring configured to slide over the locking ramp to a final position where the spring clip forces the mounting rail and the photovoltaic module frame against each other. In these and other examples, the locking ramp may include a profile that facilitates sliding of the centering ring over the locking ramp in a first direction and prevents sliding of the centering ring over the locking ramp in a second direction out of the final position when moved to the final position.

In some examples, the mounting rail may include a slot, and at least a portion of the spring clip may be configured to be inserted through the slot to couple the spring clip to the mounting rail. In these and other examples, the module mounting system may further include a second photovoltaic module frame adjacent to the photovoltaic module frame. The photovoltaic module frame and the second photovoltaic module frame may include a first flange and a second flange, respectively, wherein the first flange and the second flange extend in opposite directions. The first flange and the second flange may each engage a top surface of the mounting rail, and the first flange and the second flange may each include a respective aperture. The spring clip may include first and second arms configured to protrude into the apertures of the first and second flanges to facilitate rotation of the spring clip and secure the first and second photovoltaic module frames in place relative to the mounting rail. In these and other examples, the slot may be shaped to include a locking ramp having a protruding shape that facilitates sliding the portion of the spring clip inserted into the slot in the first direction to a final position and prevents the spring clip inserted into the slot in the second direction from sliding out of the final position.

Example 2 includes a spring clip, which may include an upper member having one or more arms. The spring clip may include a lower member including a central ring, wherein the upper and lower members are configured to rotate relative to each other about a hinge point to transition from an initial position to a final position, wherein the final position results in the arms of the upper member engaging the photovoltaic module frame and the central ring of the lower member engaging the mounting rail to force the mounting rail and the photovoltaic module frame against each other.

In some examples, the hinge point may include a post in one of the upper and lower members at a junction between the upper and lower members and include a hole through which the post protrudes into the other of the upper and lower members. In these and other examples, the arms of the upper member may be configured to rotate from below the photovoltaic module frame to above the photovoltaic module frame such that the arms of the upper member press against the top surface of the photovoltaic module frame at a final position.

In some examples, the mounting rail of the photovoltaic module frame may include one or more holes, and the end of the lower member may be configured to extend through the holes of the mounting rail to form a pivot point that facilitates rotation of the spring clip relative to the mounting rail.

In some examples, the arms of the upper member may extend upwardly and be sized to extend through corresponding holes in the mounting rail and the photovoltaic module frame to engage a top surface of the photovoltaic module frame, and a majority of the upper member extends below the top surface of the mounting rail.

Example 3 includes a module mounting system comprising a mounting purlin and a photovoltaic module frame, the mounting purlin comprising one or more mounting flanges extending horizontally from the mounting purlin, and the photovoltaic module frame comprising one or more frame flanges extending horizontally from the photovoltaic module frame, wherein each frame flange can abut against a corresponding mounting flange of the mounting purlin. The module mounting system may include one or more threadless clips engaged with the mounting flange and the frame flange, wherein each threadless clip includes one or more outer walls and one or more inner walls formed from a continuous sheet of material in a generally W-shaped profile.

In some examples, the gap between the tops of the inner walls may be wider than the gap between the bottoms of the inner walls.

In some examples, the height of each inner wall may be greater than the height of each outer wall. In these and other examples, the threadless clamp may include a groove in the inner wall that extends a majority of a length of the threadless clamp, wherein the threadless clamp engages the mounting flange and the frame flange at least in the groove. In these and other examples, the threadless clamp may include a plurality of grounding teeth positioned along the slots, the grounding teeth configured to engage a surface of the frame flange and bite through an anodized layer of the frame flange to electrically couple the frame flange and the mounting flange.

In some examples, one or more of the outer walls may include a plurality of locking tabs positioned in an upward-facing direction along respective edges of the outer walls. The outer walls may each include a locking recess located along the same respective edge of the outer wall as the plurality of locking tabs, wherein the locking recess is located closer to a center of the respective edge of the outer wall than the plurality of locking tabs and has a lower height than the plurality of locking tabs. In these and other examples, each threadless clamp may include a cut-out portion at a transition between the outer wall and the inner wall, with material connecting the inner wall and the outer wall at both ends of the cut-out portion. In these and other examples, each mounting flange may include an edge lip such that the respective edge lip engages with a locking recess of the respective threadless clamp.

The various features shown in the drawings may, but are not necessarily, drawn to scale. The illustrations presented in this disclosure are not meant to be actual views of any particular apparatus (e.g., device, system, etc.) or method, but are merely idealized representations which are employed to describe various embodiments of the present disclosure. Accordingly, the dimensions of the various features may be arbitrarily expanded or reduced for clarity. In addition, some of the figures may be simplified for clarity. Accordingly, the figures may not depict all of the components of a particular apparatus (e.g., device) or all of the operations of a particular method.

The terms used in the present disclosure and particularly in the appended claims (e.g., the bodies of the appended claims) are generally intended as "open terms" (e.g., the term "comprising" should be construed as "including but not limited to").

Furthermore, if a specific number of an introduced claim recitation is intended, such an intent will be explicitly recited in the claim, and in the absence of such recitation no such intent is present. For example, as an aid to understanding, the following appended claims may contain usage of the introductory phrases "at least one" and "one or more" to introduce claim recitations. However, the use of such phrases should not be construed to imply that the introduction of a claim recitation by the indefinite articles "a" or "an" limits any particular claim containing such introduced claim recitation to embodiments containing only one such recitation, even when the same claim includes the introductory phrases "one or more" or "at least one" and indefinite articles such as "a" or "an" (e.g., "a" and/or "an" should be interpreted to mean "at least one" or "one or more"); the same holds true for the use of definite articles used to introduce claim recitations.

Furthermore, even if a specific number of an introduced claim recitation is explicitly recited, those skilled in the art will recognize that such recitation should be interpreted to mean at least the recited number (e.g., the bare recitation of "two recitations," without other modifiers, means at least two recitations, or two or more recitations). Further, where those conventions are used similar to at least one of "A, B and C, etc." or one or more of "A, B and C, etc.", such structures are generally intended to include a separate a, a separate B, a separate C, A and B together, a and C together, B and C together, or A, B and C together, etc.

Furthermore, any non-conjunctive word or phrase preceding two or more alternative terms, whether in the description, claims, or drawings, should be understood to contemplate the possibilities of including one of the terms, either of the terms, or both of the terms. For example, the phrase "a or B" should be understood to include the possibility of "a" or "B" or "a and B".

All examples and conditional language recited in the disclosure are intended for pedagogical purposes to aid the reader in understanding the disclosure and the concepts contributed by the inventor to furthering the art, and are to be construed as being without limitation to such specifically recited examples and conditions. Although embodiments of the present disclosure have been described in detail, various changes, substitutions, and alterations can be made hereto without departing from the spirit and scope of the present disclosure.

Claims (20)

1. A spring clip, comprising:

a photovoltaic module frame engagement section configured to engage with a photovoltaic module frame; and

a mounting rail engagement section configured to engage with a mounting rail, the mounting rail further shaped to engage with a photovoltaic module frame;

wherein the photovoltaic module frame engagement section and the mounting rail engagement section are configured to collectively apply a compressive force that engages the mounting rail and the photovoltaic module frame with each other.

2. The spring clip of claim 1, wherein:

the engagement section of the spring clip includes at least a first wing configured to be positioned on a top surface of a first flange of a photovoltaic module frame and a second wing configured to be positioned on a top surface of a flange of a second photovoltaic module frame.

3. The spring clip of claim 1, wherein:

the mounting rail engagement section of the spring clip includes a centering ring configured to slide over a locking ramp portion formed on a surface of a mounting rail.

4. A spring clip according to claim 3, wherein said centering ring maintains a locked position relative to a locking ramp.

5. The spring clip of claim 1, wherein at least a portion of the spring clip is configured to be inserted through a slot formed in a mounting rail.

6. The spring clip of claim 1, wherein at least a portion of the spring clip comprises at least one arm configured to protrude into a hole formed in a flange extending from a photovoltaic module frame.

7. The spring clip of claim 5 wherein the slot is shaped to include a locking ramp having a protruding shape that facilitates sliding a portion of the spring clip inserted through the slot in a first direction to a final position and prevents sliding the spring clip inserted through the slot in a second direction out of the final position.

8. A spring clip, comprising:

an upper component comprising one or more arms; and

a lower member comprising a central ring, wherein the upper and lower members are configured to rotate relative to each other about a hinge point to transition from an initial position to a final position, the final position resulting in engagement of the arms of the upper member with the photovoltaic module frame and the central ring of the lower member with the mounting rail to force the mounting rail and the photovoltaic module frame against each other.

9. The spring clip of claim 8, wherein the hinge point is located at a junction between the upper and lower members, the hinge point including a post in one of the upper and lower members, and including an aperture in the other of the upper and lower members and passing through the post.

10. The spring clip of claim 9, wherein the arm of the upper member is configured to rotate from below the photovoltaic module frame to above the photovoltaic module frame such that the arm of the upper member presses against a top surface of the photovoltaic module frame at a final position.

11. The spring clip of claim 8, wherein:

the mounting rail includes one or more holes; and

the end of the lower member is configured to extend through the aperture of the mounting rail to form a pivot point that facilitates rotation of the spring clip relative to the mounting rail.

12. The spring clip of claim 8, wherein the arm portion of the upper member extends upwardly and is sized to extend through corresponding holes in both the mounting rail and the photovoltaic module frame to engage a top surface of the photovoltaic module frame and a majority of the upper member extending below the top surface of the mounting rail.

13. A module mounting system, comprising:

a mounting purlin comprising one or more mounting flanges extending horizontally from the mounting purlin, wherein each of the one or more mounting flanges is configured to engage a corresponding frame flange formed on a photovoltaic module frame; and

one or more threadless clamps engaged with the mounting flange and the frame flange, each threadless clamp comprising one or more outer walls and one or more inner walls formed in a generally W-shaped profile.

14. The module mounting system of claim 13, wherein a gap between the tops of the inner walls is wider than a gap between the bottoms of the inner walls.

15. The module mounting system of claim 13, wherein the height of each of the inner walls is greater than the height of each of the outer walls.

16. The module mounting system of claim 15, wherein the screwless clamp includes a slot in the inner wall extending a majority of a length of the screwless clamp, the screwless clamp engaging the mounting flange and the frame flange at least in the slot.

17. The module mounting system of claim 16, wherein the threadless clamp comprises a plurality of grounding teeth positioned along the slots, the grounding teeth configured to engage a surface of the frame flange and bite through an anodized layer of the frame flange to electrically couple the frame flange and the mounting flange.

18. The module mounting system of claim 13, wherein one or more of the outer walls comprises:

a plurality of locking tabs positioned in an upward facing direction along respective edges of the outer wall; and

a locking recess located along the same respective edge of the outer wall as the plurality of locking tabs, the locking recess being located closer to a center of the respective edge of the outer wall than the plurality of locking tabs and having a lower height than the plurality of locking tabs.

19. The module mounting system of claim 18, wherein each threadless clip includes a cut-out portion at a transition between the outer wall and the inner wall, the cut-out portion having material connecting the inner wall and the outer wall at both ends.

20. The module mounting system of claim 18, wherein each of the mounting flanges includes an edge lip such that the respective edge lip engages with the locking recess of the respective threadless clamp.

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