WO2022035755A1

WO2022035755A1 - Multifunctional features for alignment, attachment and reinforcement of mounting connections for pv panels

Info

Publication number: WO2022035755A1
Application number: PCT/US2021/045210
Authority: WO
Inventors: Andres F. CAVIERES PINILLA
Original assignee: The Board Of Regents Of The University Of Oklahoma
Priority date: 2020-08-10
Filing date: 2021-08-09
Publication date: 2022-02-17

Abstract

Mounting systems for solar panel assemblies and related methods are generally described. In some embodiments, a solar panel base rail may include one or more alignment stops extending parallel from a horizontal flange of the base rail. The alignment stops may be configured to be bent upward or downward at any suitable angle to secure a fastener to the solar panel assembly.

Description

MULTIFUNCTIONAL FEATURES FOR ALIGNMENT, ATTACHMENT AND REINFORCEMENT OF MOUNTING CONNECTIONS FOR PV PANELS

CROSS-REFERENCE TO RELATED APPLICATIONS

[001] This application claims the benefit of priority under 35 U.S.C. § 119(e) of U.S.

Provisional Application Serial No. 63/063,890, filed August 10, 2020, the disclosure of which is incorporated herein by reference in its entirety.

FIELD

[002] The technology is generally related to photovoltaic fastener systems and methods.

BACKGROUND

[003] The most common approach to mechanically attach and electrically bond solar panels (e.g., solar photovoltaic (PV) panels) on a mounting structure is by the use of conventional fasteners involving bolts, nuts, washers or rivets. PV mounting solutions that rely on conventional bolted connections are common in all major solar markets, including residential and commercial building rooftops, solar carports and canopies, as well as utility scale ground mount applications, both in fixed tilt and trackers.

SUMMARY

[004] In one aspect, mounting systems are provided. In some embodiments, a mounting system for mounting a solar panel assembly to a base assembly includes a base rail, a panel rail, and one or more spring clamps. In some embodiments, the base rail includes a base horizontal flange, a first plurality of alignment stops extending upward from the base horizontal flange, and a second plurality of alignment stops extending downward from the base horizontal flange. In some embodiments, panel rail includes a panel horizontal flange. The one or more spring clamps may be configured to secure the panel horizontal flange to the base horizontal flange, wherein each of the one or more spring clamps is configured to be attached to the base horizontal flange proximate to a corresponding pair of the second plurality of alignment stops.

[005] In some embodiments, the panel horizontal flange is aligned on the base horizontal flange using the first plurality of alignment stops on the base horizontal flange. [006] In some embodiments, each pair of the second plurality of alignment stops maintains an optimal alignment and load distribution of the corresponding spring clamp with respect to the panel horizontal flange and the base horizontal flange during loading events.

[007] In another aspect, mounting systems are provided. In some embodiments, a mounting system for mounting a structure to a base assembly includes a base including a base horizontal flange, a plurality of receiver notches formed in the base horizontal flange, a plurality of alignment stops formed in the base horizontal flange, wherein each receiver notch is associated with at least two alignment stops, and wherein the alignment stops are configured to be deformed out of plane from the base horizontal flange, a rail, wherein the rail comprises a second horizontal flange, and one or more spring clamps configured to secure the second horizontal flange to the base horizontal flange, wherein each of the one or more spring clamps is attached to the base horizontal flange at a receiver notch with the associated at least two alignment stops deformed in a first direction oriented out of plane with the base horizontal flange.

[008] In yet another aspect, mounting systems are provided. In some embodiments, a mounting system for mounting a structure to a base assembly includes a base horizontal flange, a plurality of receiver notches formed in the base horizontal flange, a plurality of alignment stops formed in the base horizontal flange, wherein each receiver notch is associated with at least two alignment stops, and wherein the alignment stops are configured to be deformed out of plane from the base horizontal flange, and a plurality of clamp slots formed in the base horizontal flange, and wherein the clamp slots are configured to receive a corresponding locking tab of one or more spring clamps configured to clamp a rail to the base horizontal flange.

[009] In any of the embodiments above, a mounting system includes a plurality of clamp slots formed in the base horizontal flange. In some embodiments, the locking tabs of the one or more spring clamps are engaged with at least a portion of the plurality of clamp slots.

[010] In any of the embodiments above, the plurality of clamp slots are formed inward from the plurality of receiver notches and the plurality of alignment stops in the base horizontal flange.

[Oil] In any of the embodiments above, at least a portion of the plurality of alignment stops are deformed in a second direction out of plane with the base horizontal flange. In some embodiments, the second direction is opposite from the first direction. [012] In any of the embodiments above, the portion of the plurality of alignment stops deformed in the second direction align the second horizontal flange with the base horizontal flange.

[013] In any of the embodiments above, the structure is hung from a top inner corner of the second horizontal flange by the portion of the plurality of alignment stops deformed in the second direction.

[014] In any of the embodiments above, a portion of the alignment stops that are deformed in the first direction function as a bearing structure that increases a capacity of the one or more spring clamps to prevent slippage caused by lateral load along a main direction of the base.

[015] In any of the embodiments above, a portion of the plurality of alignment stops that are deformed in the first direction provide additional bracing and lateral stability of a corresponding spring clamp of the one or more spring clamps with respect to the second horizontal flange and the base horizontal flange.

[016] In any of the embodiments above, the base includes two adjacent bases, and the rail is restrained by a portion of the plurality of alignment stops on the two adjacent bases deformed in a second direction opposite from the first direction to prevent slippage caused by lateral loads transverse to a main direction of the two adjacent bases.

[017] In any of the embodiments above, the structure is a solar panel assembly, the rail is a panel rail, and the base is a base rail.

[018] In any of the embodiments above, the plurality of alignment stops are configured to be deformed in a first direction out of plane with the base horizontal flange and a second direction out of plane with the base horizontal flange. In some embodiments, the second direction is opposite from the first direction.

[019] In any of the embodiments above, the plurality of receiver notches are configured to receive a spring clamp of the one or more spring clamps when the associated at least two alignment stops are deformed in the first direction.

[020] In any of the embodiments above, when a portion of the plurality of alignment stops are deformed in the second direction, the portion of the plurality of alignment stops are configured to align the rail and the base.

[021] In any of the embodiments above, the plurality of alignment stops are configured to function as a bearing structure that increases a capacity of the one or more clamps to prevent slippage caused by lateral load along a main direction of the base when the alignment stops are deformed in the first direction. [022] In any of the embodiments above, the plurality of alignment stops are configured to provide additional bracing and lateral stability of a corresponding spring clamp of the one or more spring clamps when the alignment stops are deformed in the first direction.

[023] In any of the embodiments above, the plurality of clamp slots are formed inward from the plurality of receiver notches and the plurality of alignment stops in the base horizontal flange.

BRIEF DESCRIPTION OF THE DRAWINGS

[024] The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate one or more implementations described herein and, together with the description, explain these implementations. The drawings are not intended to be drawn to scale, and certain features and certain views of the figures may be shown exaggerated, to scale or in schematic in the interest of clarity and conciseness. Not every component may be labeled in every drawing. Like reference numerals in the figures may represent and refer to the same or similar element or function.

[025] FIGs. 1A-1D present various views of a series of photovoltaic panels attached in a portrait orientation to a series of base rails according to some embodiments;

[026] FIG. 2 presents a close-up interior perspective view of the solar panel frame connected to the support base rail from FIGs. 1A-1D, according to some embodiments;

[027] FIG. 3 presents a top view of the base horizontal flange from FIGs. 1A-1D, according to some embodiments;

[028] FIG. 4 presents a front perspective view of a spring clamp according to some embodiments;

[029] FIG. 5 presents a rear perspective view of a spring clamp according to some embodiments;

[030] FIG. 6 presents a front view of a spring clamp in a compressed state, according to some embodiments;

[031] FIG.7 presents a front view of a spring clamp in a relaxed state, according to some embodiments;

[032] FIG. 8A presents a perspective view of a spring clamp approaching a panel rail and a base rail, according to some embodiments; [033] FIG. 8B presents a rear cross-sectional view of the spring clamp of FIG. 8A approaching the panel horizontal flange and the base horizontal flange, according to some embodiments;

[034] FIG. 8C presents a side cross-sectional view of the spring clamp of FIG. 8A approaching the panel horizontal flange and the base horizontal flange, according to some embodiments;

[035] FIG. 9A presents a perspective view of the spring clamp of FIG. 8A partially engaged with the panel rail and the base rail, according to some embodiments;

[036] FIG. 9B presents a rear cross-sectional view of the spring clamp of FIG. 8A partially engaged with the panel horizontal flange and the base horizontal flange, according to some embodiments;

[037] FIG. 9C presents a side cross-sectional view of the spring clamp of FIG. 8A partially engaged with the panel horizontal flange and the base horizontal flange, according to some embodiments;

[038] FIG. 10A presents a perspective view of the spring clamp of FIG. 8A fully engaged with the panel rail and the base rail, according to some embodiments;

[039] FIG. 10B presents a rear cross-sectional view of the spring clamp of FIG. 8A fully engaged with the panel horizontal flange and the base horizontal flange, according to some embodiments;

[040] FIG. 10C presents a side cross-sectional view of the spring clamp of FIG. 8A fully engaged with the panel horizontal flange and the base horizontal flange, according to some embodiments;

[041] FIG. 11 presents a series of solar panel assemblies mounted in portrait orientation over a base assembly with a rotating shaft that programmatically follows the sun, according to some embodiments;

[042] FIG. 12 presents the base assembly of FIG. 1 lin a state prior to the attachment of the solar panel assemblies, when the base rails may not be equally spaced, parallel to each other or perpendicular to the supporting rotational shaft, according to some embodiments;

[043] FIG. 13A presents a portion of a base rail according to some embodiments;

[044] FIG. 13B presents a top view of a base horizontal flange comprising alignments stops, receiver notches and clamp slots, according to some embodiments;

[045] FIG. 14A presents a top perspective view of an assembly of two solar panels, according to some embodiments;

[046] FIGs. 14B-14E present various detail views of FIG. 14A; [047] FIGs. 15A-15K present a sequence of steps for spacing, alignment and attachment of panel frames on top of base horizontal flanges, , according to various embodiments;

[048] FIGs. 16A-16E present various views of alignment stops, according to some embodiments;

[049] FIGs. 17A-17B present side views of alignment stops bent downward, according to some embodiments; and

[050] FIG. 18 presents a side view of alignment stops bent downwardly, according to some embodiments.

DETAILED DESCRIPTION

[051] Fasteners such as bolted connections are conventionally used to assemble PV assemblies to a mounting structure in a variety of solar markets. The Inventors have recognized that the use of conventional fasteners pose several problems. First, panel dimensions and the position of mounting holes in panel frames are not typically standardized across manufacturers. This lack of standardization requires vendors to customize mounting hardware for each solar project to match the specifications of different panels, which can extend manufacturing lead times and increase supply chain costs. Second, the use of bolted connections can increase the complexity and time required for panel installation, along with the risk of installer error. For example, mounting holes at the bottom of PV panel frames may need to be manually aligned with mating holes in the supporting structure (e.g. mounting rails), then bolts may need to be threaded, washers inserted, and nuts temporarily placed. These steps are taken four times for each PV panel, typically in conditions that are not ergonomic or comfortable for the installers. In each instance, these parts and tools may be missing, lost, stolen, or fall over the panels, potentially causing damage to the solar cells. Finally, nuts and bolts must be tightened at specific torque values, which in practice is very difficult to achieve. Over-torqueing is a common cause for the failure of bolts under high wind loads, whereas under-torqueing may lead to loose bolts and nuts, due to vibrations and other environmental conditions. This adds maintenance costs by requiring constant checking and re-tightening of large numbers of bolts and nuts on site.

[052] Currently, only a few fasteners provide mechanical attachment of PV panels with integrated bonding without relying on bolted connections and specialized tools. Further, the Inventors have recognized that the existing commercial solutions tend to be complicated to install, by requiring installation without complete visibility, or pre-attachment of fastener into the frame of PV panels, thus frustrating efforts to provide an easily repeatable installation.

[053] Moreover, most of these solutions only admit the attachment of PV panels in the so-called landscape orientation, where two rails or beams are placed underneath the panel, providing a maximum of four connection points. This condition hinders the possibility of making use of more connection points to provide a more uniform load distribution against uplift and lateral forces caused by strong wind gusts. While some of the existing commercial solutions can be used for attachment of PV panels in the so-called portrait orientation, the Inventors have recognized that they can be difficult and time consuming to install correctly, and are prone to detachment under dynamic loading conditions. It is to these and other deficiencies in the prior art that the present mounting system is directed.

[054] In view of the above, the Inventors have recognized the benefits associated with a system for expediting the attachment of a solar panel on a support member in a landscape orientation.

[055] Before describing various embodiments of the present disclosure in more detail by way of exemplary description, examples, and results, it is to be understood as noted above that the present disclosure is not limited in application to the details of methods and apparatus as set forth in the following description. The present disclosure is capable of other embodiments or of being practiced or carried out in various ways. As such, the language used herein is intended to be given the broadest possible scope and meaning; and the embodiments are meant to be exemplary, not exhaustive. Also, it is to be understood that the phraseology and terminology employed herein is for the purpose of description and should not be regarded as limiting unless otherwise indicated as so. Moreover, in the following detailed description, numerous specific details are set forth in order to provide a more thorough understanding of the disclosure. However, it will be apparent to a person having ordinary skill in the art that the embodiments of the present disclosure may be practiced without these specific details. In other instances, features which are well known to persons of ordinary skill in the art have not been described in detail to avoid unnecessary complication of the description.

[056] Unless otherwise defined herein, scientific and technical terms used in connection with the present disclosure shall have the meanings that are commonly understood by those having ordinary skill in the art. Further, unless otherwise required by context, singular terms shall include pluralities and plural terms shall include the singular.

[057] All patents, published patent applications, and non-patent publications mentioned in the specification are indicative of the level of skill of those skilled in the art to which the present disclosure pertains. All patents, published patent applications, and nonpatent publications referenced in any portion of this application are herein expressly incorporated by reference in their entirety to the same extent as if each individual patent or publication was specifically and individually indicated to be incorporated by reference.

[058] As utilized in accordance with the methods and apparatus of the present disclosure, the following terms, unless otherwise indicated, shall be understood to have the following meanings:

[059] The use of the word “a” or “an” when used in conjunction with the term

“comprising” in the claims and/or the specification may mean “one,” but it is also consistent with the meaning of “one or more,” “at least one,” and “one or more than one.” The use of the term “or” in the claims is used to mean “and/or” unless explicitly indicated to refer to alternatives only or when the alternatives are mutually exclusive, although the disclosure supports a definition that refers to only alternatives and “and/or.” The use of the term “at least one” will be understood to include one as well as any quantity more than one, including but not limited to, 2, 3, 4, 5, 6, 7, 8, 9, 10, 15, 20, 30, 40, 50, 100, or any integer inclusive therein. The term “at least one” may extend up to 100 or 1000 or more, depending on the term to which it is attached; in addition, the quantities of 100/1000 are not to be considered limiting, as higher limits may also produce satisfactory results. In addition, the use of the term “at least one of X, Y and Z” will be understood to include X alone, Y alone, and Z alone, as well as any combination of X, Y and Z.

[060] As used herein, all numerical values or ranges (e.g., in units of length such as micrometers or millimeters) include fractions of the values and integers within such ranges and fractions of the integers within such ranges unless the context clearly indicates otherwise. Thus, to illustrate, reference to a numerical range, such as 1-10 includes 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, as well as 1.1, 1.2, 1.3, 1.4, 1.5, etc., and so forth. Reference to a range of 1-50 therefore includes 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, etc., up to and including 50, as well as 1.1, 1.2, 1.3, 1.4, 1.5, etc., 2.1, 2.2, 2.3, 2.4, 2.5, etc., and so forth. Reference to a series of ranges includes ranges which combine the values of the boundaries of different ranges within the series. Thus, to illustrate reference to a series of ranges, for example, of 1-10, 10-20, 20-30, 30-40, 40-50, 50-60, 60-75, 75-100, 100-150, 150-200, 200-250, 250-300, 300-400, 400-500, 500-750, 750-1,000, includes ranges of 1-20, 10-50, 50-100, 100-500, and 500-1,000, for example.

[061] As used herein, the words “comprising” (and any form of comprising, such as

“comprise” and “comprises”), “having” (and any form of having, such as “have” and “has”), “including” (and any form of including, such as “includes” and “include”) or “containing” (and any form of containing, such as “contains” and “contain”) are inclusive or open-ended and do not exclude additional, unrecited elements or method steps.

[062] The term “or combinations thereof’ as used herein refers to all permutations and combinations of the listed items preceding the term. For example, “A, B, C, or combinations thereof’ is intended to include at least one of: A, B, C, AB, AC, BC, or ABC, and if order is important in a particular context, also BA, CA, CB, CBA, BCA, ACB, BAC, or CAB. Continuing with this example, expressly included are combinations that contain repeats of one or more item or term, such as BB, AAA, AAB, BBC, AAABCCCC, CBBAAA, CAB ABB, and so forth. The skilled artisan will understand that typically there is no limit on the number of items or terms in any combination, unless otherwise apparent from the context.

[063] Throughout this application, the terms “about” or “approximately” are used to indicate that a value includes the inherent variation of error. Further, in this detailed description, each numerical value (e.g., temperature or time) should be read once as modified by the term "about" (unless already expressly so modified), and then read again as not so modified unless otherwise indicated in context. As noted above, any range listed or described herein is intended to include, implicitly or explicitly, any number within the range, particularly all integers, including the end points, and is to be considered as having been so stated. For example, "a range from 1 to 10" is to be read as indicating each possible number, particularly integers, along the continuum between about 1 and about 10. Thus, even if specific data points within the range, or even no data points within the range, are explicitly identified or specifically referred to, it is to be understood that any data points within the range are to be considered to have been specified, and that the inventors possessed knowledge of the entire range and the points within the range. Unless otherwise stated, the term “about” or “approximately”, where used herein when referring to a measurable value such as an amount, length, thickness, a temporal duration, and the like, is meant to encompass, for example, variations of ± 20% or ± 10%, or ± 5%, or ± 1%, or ± 0.1% from the specified value, as such variations are appropriate to perform the disclosed methods and as understood by persons having ordinary skill in the art.

[064] As used herein, the term “substantially” means that the subsequently described parameter, event, or circumstance completely occurs or that the subsequently described parameter, event, or circumstance occurs to a great extent or degree. For example, the term “substantially” means that the subsequently described parameter, event, or circumstance occurs at least 90% of the time, or at least 91%, or at least 92%, or at least 93%, or at least 94%, or at least 95%, or at least 96%, or at least 97%, or at least 98%, or at least 99%, of the time, or means that the dimension or measurement is within at least 90%, or at least 91%, or at least 92%, or at least 93%, or at least 94%, or at least 95%, or at least 96%, or at least 97%, or at least 98%, or at least 99%, of the referenced dimension or measurement (e.g., length).

[065] As used herein any reference to "one embodiment" or "an embodiment" means that a particular element, feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment. The appearances of the phrase "in one embodiment" in various places in the specification are not necessarily all referring to the same embodiment.

[066] Where applicable, although state diagrams, flow diagrams or both may be used to describe embodiments, the present disclosure is not limited to those diagrams or to the corresponding descriptions. For example, flow need not move through each illustrated box or state, or in exactly the same order as illustrated and described. Methods of the present disclosure may be implemented by performing or completing manually, automatically, or a combination thereof, selected steps or tasks. The term “method” may refer to manners, means, techniques and procedures for accomplishing a given task including, but not limited to, those manners, means, techniques and procedures either known to, or readily developed from known manners, means, techniques and procedures by practitioners of the art to which the invention belongs.

[067] It should be noted that where reference is made herein to a method comprising two or more defined steps, the defined steps can be carried out in any order or simultaneously (except where context excludes that possibility), and the method can also include one or more other steps which are carried out before any of the defined steps, between two of the defined steps, or after all of the defined steps (except where context excludes that possibility). Still further, additional aspects of the various embodiments of the instant disclosure may be found in one or more appendices attached hereto and/or filed herewith, the disclosures of which are incorporated herein by reference as if fully set out at this point.

[068] Turning now to the figures, several nonlimiting embodiments are described in further detail. However, it should be understood that the disclosure is not limited to only these specific embodiments and that appropriate combinations and modifications of the components and methods disclosed in relation to the figures are also envisioned as the disclosure is not limited in this fashion. [069] Beginning with FIG. 1A, shown therein is a bottom view of a plurality of solar panel assemblies 100 affixed to a base assembly 102 with a plurality of base rails 112 according to some embodiments. Each solar panel assembly 100 includes a photovoltaic (PV) panel 106 attached to a panel frame 108. The panel frame 108 includes one or more panel rails 110 that extend along at least one side of the PV panel 106. In some embodiments, as shown in FIGs. 1A-1D, the panel frame 108 includes a pair of panel rails 110 that extend along the length of the PV panel 106. As depicted in FIG. 1A, the PV panels 106 may be mounted to the base assembly 102 in a “portrait” configuration in which the panel rails 110 are mounted in a parallel relationship to the base rails 112 of the base assembly 102. Each panel rail 110 includes a panel vertical wall 114 for supporting the PV panel 106 and a panel horizontal flange 116 for connection to the base rail 112 (as depicted in FIG. 2).

[070] As depicted in FIGs. 1A-1D, the base assembly 102 may be supported by, or attached to, a fixed structure (such as a roof, canopy or ground mounted structure) or to an articulating carrier that adjusts the angular position of the solar panel assembly 100 to optimize the collection of light. For example, the base assembly 102 can be connected to a plurality of rotating shafts 142 that automatically or programmatically orients the solar panel assembly 100 with respect to a light source.

[071] Turning to FIG. 2, shown therein is an interior perspective view of a portion of the solar panel assembly 100 and base assembly 102. The panel frame 108 includes a panel vertical wall 114 and a panel horizontal flange 116. The base rail 112 includes a base vertical wall 118 and a base horizontal flange 120. During installation, the panel frame 108 is positioned with respect to the base assembly 102 such that the panel horizontal flange 116 is aligned with the base horizontal flange 120. As noted in FIG. 2, the clamp 104 captures and secures the panel horizontal flange 116 to the base horizontal flange 120. In many embodiments, the spring clamps 104, panel rails 110 and base rails 112 are each constructed from an electrically conductive metal.

[072] As illustrated in the top view of the base horizontal flange 120 in FIG. 3, the base horizontal flange 120 includes alignment stops 122 and clamp slots 124 that engage with the spring clamp 104. As discussed below, the alignment stops 122 can be bent upward or downward from the base horizontal flange 120 to assist with the engagement of the spring clamp 104 or with the alignment of the panel rails 110. In some embodiments, the alignment stops 122 are created during manufacture by punching and folding the portion of the base horizontal flange 120 removed to create the clamp slots 124. FIG. 3 depicts an exemplary embodiment of the number, size and position of alignment stops 122 and clamps slots 124, notwithstanding the number, size and positions of alignment stops 122 and clamp slot 124 may differ. In other embodiments, a custom punch and die can be used to produce the alignment stops 122 and clamp slots 124 on existing base assemblies 102. Additional views of the alignment stops and clamp slots are presented in FIGs. 8B-8C, FIGs. 9B-9C, and FIGs. 1 OB -10C, following the sequence of insertion and attachment of the spring clamp 104.

[073] Turning to FIGs. 4-6, shown therein are front perspective, rear perspective, rear and front views of the spring clamp 104. The construction and use of the spring clamp in connection with the mounting of solar panels in a “portrait” orientation is disclosed in WO 2020/076870 Al, the disclosure of which is fully incorporated by reference as if fully set forth herein. In exemplary embodiments, the spring clamp 104 is made from a stamped spring-grade steel sheet metal with anti-corrosion properties (e.g., stainless, or galvanized). The spring clamp 104 may be constructed of materials including, but not limited to, metals such as steel, stainless steel, aluminum, and titanium, and metal alloys, ceramic composites, composite reinforced metals, plastics and the like. In one embodiment, the spring clamp 104 is constructed from a conductive metal to provide a grounding path between the panel rail 110 and the base rail 112.

[074] In some embodiments, a spring clamp 104 includes a clamp body 126 with two or more legs 128 extending away in an oblique angle from a common apex 130. In some embodiments, the spring clamp 104 may be “V” shaped or any other suitable shape with two or more legs, as the present disclosure is not limited by the shape of the spring clamp. The thickness of the clamp body 126 and the material of construction permit the legs 128 to be approximated or compressed toward one another, as illustrated in FIG. 7. When the compressive force is removed, the spring energy stored within the spring clamp 104 forces the legs 128 to separate into a relaxed state, as illustrated in FIG. 6.

[075] In some embodiments, the angle between the two legs 128 may be between about 55° and about 75° when the spring clamp 104 is in a relaxed state. In some embodiments, the legs 128 may form an angle from the apex 130 of about 60° when the spring clamp 104 is in a relaxed state. Of course, other arrangements of the legs 128 are also contemplated. For example, the legs 128 may be angled at least at 45°, 50°, 55°, 60°, 65°, 70°, 75°, 80°, 85°, 90°, and/or any other suitable angle, such as less than or equal to 90°, 85°, 80°, 75°, 70°, 65°, 60°, 55°, 50°, 45°, and/or any other suitable angle. Combinations of ranges for the angle of the legs in the relaxed state are also contemplated, including between 40° and 100°, between 30° and 120°, between 50° and 80°, and/or any other suitable combination. It should be appreciated that the present disclosure is not limited by the angle of the clamp legs in the relaxed state.

[076] Each leg 128 has a receiver slot 132 that extends from the front of the leg 128 to an interior portion of the leg 128. As best illustrated in FIG. 4, the receiver slots 132 are arranged in a substantially normal, or orthogonal, relationship with respect to the legs 128 such that the receiver slots 132 are angled downward in an oblique manner when the spring clamp 104 is in a relaxed state. When in a compressed state (as illustrated in FIG. 6), and due to the angular disposition of the legs 128 and the orientation of the receiver slots 132 within the legs 128, the receiver slots 132 together provide a first clearance (Ci) that represents the height of the linear gap that extends through the two receiver slots 132. When the legs 128 of the spring clamp 104 are in a relaxed state (as illustrated in FIG. 7), the angular disposition of the legs 128 and the receiver slots 132 is reduced to provide a second clearance (C2) that is less than the first clearance (Ci).

[077] In some embodiments, each of the receiver slots 132 includes a plurality of teeth 134. The serrated edges of the receiver slots 132 are configured to scratch the surface of a base rail 112 to increase the frictional resistance between the spring clamp 104, and the base rail 112, and/or any other suitable structure of the assembly. The teeth 134 also increase the electrical conductivity between the spring clamp 104 and the base rail 112 by removing any non-conductive coatings applied to these components.

[078] Each leg 128 of the spring clamp 104 is conceived to facilitate the use of pliers or other tools for compressing the legs 128 of the spring clamp 104. In some embodiments, each leg 128 includes a slot or hole (not depicted) that is configured to receive a corresponding post or tab on a custom-made tool to facilitate the engagement of the compression tool with each leg 128.

[079] The clamp 104 also includes a pair of locking tabs 138 that extend outward from the legs 128. The locking tabs 138 have a thickness that is less than the width of the clamp slots 124 in the base horizontal flange 120. During installation, the locking tabs 138 are initially retained between the alignment stops 122 to capture the clamp 104 in a compressed state. Once the clamp 104 advances further onto the panel horizontal flange 116 and base horizontal flange 120, the locking tabs 138 clear the alignment stops 122 and the legs 128 are allowed to partially open such that and the locking tabs 138 are forced upward within the clamp slots 124. In this fully engaged position, the locking tabs 138 are captured within the clamp slots 124 to prevent the retraction of the clamp 104 from the panel horizontal flange 116 and base horizontal flange 120. [080] The sequence of FIGs. 8A-10C demonstrates an exemplary method of installing the clamp 104 onto the panel horizontal flange 116 and base horizontal flange 120. Beginning with FIGs. 8A-8C, the clamp 104 is laterally aligned with a series of alignment stops 122 on the base horizontal flange 120. Once the panel horizontal flange 116 and base horizontal flange 120 have been aligned, the legs 128 of the clamp 104 are compressed together with an external compressive force generated by pliers, or a custom tool.

[081] Once the legs 128 have been compressed to an extent at which the locking tabs

138 will fit between the alignment stops 122, the clamp 104 is pushed forward such that the panel horizontal flange 116 and base horizontal flange 120 fit within the increased clearance (Ci) of the receiver slots 132, as indicated in FIGs. 9A-9C. The progress of the clamp 104 can be paused with the clamp in a partially engaged position while the locking tabs 138 are positioned between the alignment stops 122. The alignment stops 122 oppose the outward spring force exerted by the clamp 104 and the compressive force applied to the feet 136 can be reduced or withdrawn. In this partially engaged position, the installer can verify that the clamp 104 is properly aligned with respect to the panel horizontal flange 116 and base horizontal flange 120.

[082] Next, the clamp 104 is advanced onto the panel horizontal flange 116 and base horizontal flange 120, as illustrated in FIGs. 10A-10C. Once the locking tabs 138 clear the alignment stops 122, the legs 128 are permitted to partially expand outward and the locking tabs 138 are captured within the clamp slots 124 of the base horizontal flange 120. In this fully engaged position, the clamp 104 exerts a compressive force onto the panel horizontal flange 116 and base horizontal flange 120 through the serrated receiver slots 132. The alignment stops 122 and clamp slots 124 cooperate to prevent the locking tabs 138 and clamp 104 from being retracted from the panel horizontal flange 116 and base horizontal flange 120. To unlock and remove the clamp 104, the legs 128 may be compressed together so that the locking tabs 138 can clear the alignment stops 122 as the clamp 104 is withdrawn.

[083] An example of a base assembly 102, with a plurality of solar panel assemblies

100 affixed in a portrait orientation is illustrated in FIG. 11. In this configuration, each pair of adjacent solar panel assemblies 100 is affixed to the base assembly 102 by means of single base rail 112 that is shared between them. In some embodiments, the base rails 112 to be positioned at the same distance from one another, at a distance corresponding roughly to the width of the solar panel assembly 100 being affixed. Moreover, base rails 112 may be substantially parallel to each other, and substantially perpendicular to a reference line or structural member supporting such base rails, prior the installation of the solar panel assemblies 100. FIG. 11 provides an example of the equal distancing, parallelism, and perpendicularity of the solar panel assemblies 100 after installation. However, the conditions of equal distancing, parallelism, and perpendicularity cannot always be readily achieved or maintained, making the attachment of solar panels difficult and laborious, as illustrated in FIG. 12. Additionally, environmental conditions and forces may shift the position and angle of the base rails 112 after the installation of solar panel assemblies 100, causing the detachment of the panel horizontal flange 116 from the base rails 112.

[084] FIGs. 131A-13B illustrates a different embodiment of alignment stops 122 and clamp slots 124 that ensures the conditions of spacing, parallelism and perpendicularity desirable for installation and operation of the solar panel assemblies 100. FIG. 13A depicts a portion of an exemplary base rail 112, with a plurality of alignment stops 122 and clamp slots 124, according to some embodiments. FIG. 13B depicts a top view of the clamp slots 124 and alignment stops 122, which are positioned at the edge of the base horizontal flange 120 in some embodiments. One or more receiver notches 140 separates the alignment stops 122, providing the clearance to receive the spring clamp 104. A non-limiting embodiment of the base rail 112 is shown in FIG. 13A, representing an “omega” purlin or beam, typically made of roll-formed sheet metal, and commonly used in building construction. Other base rails may have a C-shaped, Z-shaped, L-shaped or other cross-sectional configuration also commonly used in building construction. Each base rail 112 may include a vertical wall 118 and a base horizontal flange 120 where one or more solar panel assemblies may be mounted on.

[085] In the present embodiment of the base rail 112, the alignment stops 122 initially protrude horizontally in substantially the same plane as the horizontal flange 120, and toward the central receiver notch 140. The alignment stops 122 may be optionally kept parallel to the horizontal flange 120, or may be bent upwardly or downwardly, before, during or after installation of solar panels 106. In some embodiments, the alignment stops 122 are configured to be bent upward or downward at an angle from about 1 to about 90 degrees from the surface of the base horizontal flange 120.

[086] FIG 14A depicts a base assembly with two solar panels 100 attached in their final position on top of base rails 112. In this figure, the glass, solar cells and back sheet of the solar panel have been removed from the view to show the mounting of the panel horizontal flange 116 on top of the base horizontal flange 120, which are attached by means of the spring clamp 104, and where the alignment of the panel horizontal flange 116 in relation with the base horizontal flange 120 is facilitated during installation, and enforced during operation by means of the alignment stops 122 when bent upwards. As shown in the detail view FIG. 14B, the alignment stops 122 may operate as hooks, allowing an installer to hang the solar panel from the inner corners of the panel horizontal flange 116, thus providing an initial prepositioning of the solar panel on top of the base rails 112 before the execution of the final alignment. Similarly, this hook function may increase the capacity of the spring clamps to withstand lateral loads along the main direction of the base rail. FIGs. 14C-14E depict various other detail views of the base assembly shown in FIG. 14A.

[087] Turning to FIGs. 15A-15K, shown therein are various front isometric and section views of the base rail 112, the panel rail 110 and the spring clamp 104. FIGs. 15A- 15D illustrate a process of bending the alignment stops 122, as well as aligning and positioning the frame panel rail 110 on the base rail 112 with the alignment stops 122 bent upwardly according to some embodiments. It also illustrates the attachment of the spring clamp 104 to the base horizontal flange 120 and panel horizontal flange 116 with the alignment stops 122 bent downwardly (also shown in detail in FIG. 15F). The same sequence can be seen in the section views of FIGs. 15H-15K. It should be appreciated that initially, the panel rail 110 and the base rail 112 may not be properly aligned, and the outer edge of the base horizontal flange 120 may not be flush with the outer edge of the panel horizontal flange 116 (as shown in FIG. 151). The alignment stops 122 bent upward (shown in detail in FIG. 15G) from the base horizontal flange 120 may provide both a visual reference and bearing surface to enforce the proper positioning and alignment required for the successful attachment of the spring clamp 104 (as shown in FIGs. 15J-15K).

[088] The combination of upward and downward alignment stops 122 is also shown in FIGs. 16A-16E, where a portion of the panel frame 108 is affixed on top of the base rail 112. As it can be seen on the side view shown in FIG. 16A, in some embodiments, a number of alignment stops 122 may be bent upwardly (shown in detail in FIG. 16D), in more than one location along the base horizontal flange 120, and before the panel rail 110 of the panel frame 108 is affixed. In some embodiments, a number of alignment stops 122 may be bent downwards (shown in detail in FIG. 16C)in the same location where the spring clamps 104 may be attached to provide an extra connection between the panel rail 110 and the base rail 112.

[089] FIG. 16E illustrates how the upward alignment stops 122 assist in the alignment of the panel horizontal flange 116 and the base horizontal flange 120. In this way, the alignment stops 122 provide a bearing mechanism, securing the panel horizontal flange 116 and preventing it from sliding across the inner edge of the base horizontal flange 120. This bearing mechanism provided by the upward alignment stops 122 in FIG. 16D also occurs on the base rail 112 at the opposite side of the same panel frame 108 (not shown here). Both base rails 112, in combination with a number of symmetrically opposed upward alignment stops 122, work together to secure the position of the panel frame 108 against lateral loads acting across the base rails 112 in both directions (i.e., to the left or to the right). [090] When bent downwardly, the alignment stops 122 may provide a similar alignment function of previous embodiment described in FIGs. 2-7. This alignment function is depicted in FIG. 17A, where the spring clamp 104 is in a compressed state, and the locking tabs 138 are temporarily contained between the downward alignment stops 122. As illustrated in FIG. 17B, once the spring clamp 104 is fully inserted into the receiver notch 140, and the locking tabs 138 clear the alignment stops 122, the legs 128 are permitted to partially expand outward and the locking tabs 138 are captured within the clamp slots 124 of the base horizontal flange 120. In this fully engaged position, the clamp 104 exerts a compressive force onto the panel horizontal flange 116 and base horizontal flange 120 through the serrated receiver slots 132. The alignment stops 122 and clamp slots 124 cooperate to prevent the locking tabs 138 and clamp 104 from being retracted from the panel horizontal flange 116 and base horizontal flange 120. To unlock and remove the clamp 104, the legs 128 may be compressed together so that the locking tabs 138 can clear the alignment stops 122 as the clamp 104 is withdrawn.

[091] Another function of the downward alignment stops 122 is illustrated in FIG.

18, which describes the behavior of the spring clamp 104 when subject uplift wind loads in a perpendicular direction to the panel frame 108. Under these loading conditions, the panel horizontal flange 116 may attempt to separate from the base horizontal flange 120. Under significant loads, the base horizontal flange 120 and panel horizontal flange 116 may deform as the spring clamp 104 concentrates the stresses at the connection point. As the deformation in the base rail 112 and panel rail 110 increases, the spring clamp 104 may be subject to unbalanced loads, which could accelerate the failure modes for the spring clamp 104. The downward alignment stops 122 are useful in maintaining the optimal alignment of the spring clamp 104 on the panel horizontal flange 116 and base horizontal flange 120, which may significantly improve the strength of the connection and the resistance of the spring clamp 104 to deformation and failure.

[092] Thus, the spring clamp 104, the panel horizontal flange 116, the base horizontal flange 120, the clamps slots 124 and the alignment stops 122, bent upwardly and downwardly, collectively provide a “mounting system” that facilitates the attachment of the solar panel assembly 100 to the base assembly 102. The mounting system provides several advantages over the prevailing use of bolt fasteners: (1) a single clamp replaces several parts needed for a bolted connection; (2) no torque specification is necessary; (3) it is not necessary to align prefabricated bolt holes on the panel horizontal flange 116 and base horizontal flange 120; (4) electrical bonding and wire management are integrated; (5) training and quality control requirements are greatly reduced; and (6) maintenance costs are substantially reduced because nut tightening and re-torqueing of loose bolts is eliminated.

[093] Importantly, although terms of reference such as “horizontal” have been used in this disclosure, it will be understood that the mounting system is equally well suited for securing the solar panel assembly 100 to the base assembly 102 in non-horizontal applications. For example, the spring clamp 104 and the base rail 112 with alignment stops 122 and clamp slots 124, can be used to secure the PV panel 106 to a vertically-oriented base assembly 102. It will also be understood that the spring clamp 104, the base rail 112 with alignment stops 122 and clamp slots 124, along with other components of the mounting system, can be used to connect and assemble structural members used in applications other than supporting solar panels. For example, the spring clamp 104, with the base rail 112 with alignment stops 122 and clamp slots 124 may be useful in connecting structural members within the chassis of appliances or to assist with the assembly of metal buildings.

[094] It is to be understood that the present disclosure is not limited in application to the details of methods and apparatus as set forth in the following description. The present disclosure is capable of other embodiments or of being practiced or carried out in various ways. As such, the language used herein is intended to be given the broadest possible scope and meaning; and the embodiments are meant to be exemplary, not exhaustive. Also, it is to be understood that the phraseology and terminology employed herein is for the purpose of description and should not be regarded as limiting unless otherwise indicated as so. Moreover, in the detailed description, numerous specific details are set forth in order to provide a more thorough understanding of the disclosure. However, it will be apparent to a person having ordinary skill in the art that the embodiments of the present disclosure may be practiced without these specific details. In other instances, features which are well known to persons of ordinary skill in the art have not been described in detail to avoid unnecessary complication of the description.

[095] Unless otherwise defined herein, scientific and technical terms used in connection with the present disclosure shall have the meanings that are commonly understood by those having ordinary skill in the art. Further, unless otherwise required by context, singular terms shall include pluralities and plural terms shall include the singular. [096] All patents, published patent applications, and non-patent publications mentioned in the specification are indicative of the level of skill of those skilled in the art to which the present disclosure pertains. All patents, published patent applications, and nonpatent publications referenced in any portion of this application are herein expressly incorporated by reference in their entirety to the same extent as if each individual patent or publication was specifically and individually indicated to be incorporated by reference.

[097] It should be understood at the outset that, although an illustrative implementation of one or more embodiments are provided below, the disclosed systems and/or methods may be implemented using any number of techniques, whether currently known or in existence. The disclosure should in no way be limited to the illustrative implementations, drawings, and techniques illustrated below, including the exemplary designs and implementations illustrated and described herein, but may be modified within the scope of the appended claims along with their full scope of equivalents.

Claims

CLAIMS What is claimed is:

1. A mounting system for mounting a structure to a base assembly, the mounting system comprising: a base including a base horizontal flange; a plurality of receiver notches formed in the base horizontal flange; a plurality of alignment stops formed in the base horizontal flange, wherein each receiver notch is associated with at least two alignment stops, and wherein the alignment stops are configured to be deformed out of plane from the base horizontal flange; a rail, wherein the rail comprises a second horizontal flange; and one or more spring clamps configured to secure the second horizontal flange to the base horizontal flange, wherein each of the one or more spring clamps is attached to the base horizontal flange at a receiver notch with the associated at least two alignment stops deformed in a first direction oriented out of plane with the base horizontal flange.

2. The mounting system of claim 1, further comprising a plurality of clamp slots formed in the base horizontal flange, and wherein locking tabs of the one or more spring clamps are engaged with at least a portion of the plurality of clamp slots.

3. The mounting system of claim 2, wherein the plurality of clamp slots are formed inward from the plurality of receiver notches and the plurality of alignment stops in the base horizontal flange.

4. The mounting system of claim 1, wherein at least a portion of the plurality of alignment stops are deformed in a second direction out of plane with the base horizontal flange, wherein the second direction is opposite from the first direction.

5. The mounting system of claim 4, wherein the portion of the plurality of alignment stops deformed in the second direction align the second horizontal flange with the base horizontal flange. The mounting system of claim 1, wherein the structure is hung from a top inner corner of the second horizontal flange by the portion of the plurality of alignment stops deformed in the second direction. The mounting system of claim 1, wherein a portion of the alignment stops that are deformed in the first direction function as a bearing structure that increases a capacity of the one or more spring clamps to prevent slippage caused by lateral load along a main direction of the base. The mounting system of claim 1, wherein a portion of the plurality of alignment stops that are deformed in the first direction provide additional bracing and lateral stability of a corresponding spring clamp of the one or more spring clamps with respect to the second horizontal flange and the base horizontal flange. The mounting system of claim 1, wherein the base includes two adjacent bases, and the rail is restrained by a portion of the plurality of alignment stops on the two adjacent bases deformed in a second direction opposite from the first direction to prevent slippage caused by lateral loads transverse to a main direction of the two adjacent bases. The mounting system of any one of the preceding claims, wherein the structure is a solar panel assembly, the rail is a panel rail, and the base is a base rail. A mounting system for mounting a structure to a base assembly, the mounting system comprising: a base horizontal flange; a plurality of receiver notches formed in the base horizontal flange; a plurality of alignment stops formed in the base horizontal flange, wherein each receiver notch is associated with at least two alignment stops, and wherein the alignment stops are configured to be deformed out of plane from the base horizontal flange; and a plurality of clamp slots formed in the base horizontal flange, and wherein the clamp slots are configured to receive a corresponding locking tab of one or more spring clamps configured to clamp a rail to the base horizontal flange. The mounting system of claim 11, wherein the plurality of alignment stops are configured to be deformed in a first direction out of plane with the base horizontal flange and a second direction out of plane with the base horizontal flange, wherein the second direction is opposite from the first direction. The mounting system of claim 12, wherein the plurality of receiver notches are configured to receive a spring clamp of the one or more spring clamps when the associated at least two alignment stops are deformed in the first direction. The mounting system of claim 13, wherein when a portion of the plurality of alignment stops are deformed in the second direction, the portion of the plurality of alignment stops are configured to align the rail and the base. The mounting system of claim 12, wherein the plurality of alignment stops are configured to function as a bearing structure that increases a capacity of the one or more clamps to prevent slippage caused by lateral load along a main direction of the base when the alignment stops are deformed in the first direction. The mounting system of claim 12, wherein the plurality of alignment stops are configured to provide additional bracing and lateral stability of a corresponding spring clamp of the one or more spring clamps when the alignment stops are deformed in the first direction. The mounting system of claim 11, wherein the plurality of clamp slots are formed inward from the plurality of receiver notches and the plurality of alignment stops in the base horizontal flange. The mounting system of any one of claims 11-17, wherein the structure is a solar panel assembly, the rail is a panel rail, and the base is a base rail.