SISTEMA DE ACOPLAMENTO PARA USO COM UM RASTREADOR SOLAR, CLIPE PARA USO COM UM CONJUNTO DE ACOPLAMENTO DE UM RASTREADOR SOLAR, E, CONJUNTO DE ACOPLAMENTO
Patent Information
- Authority / Receiving Office
- BR · BR
- Patent Type
- Applications
- Current Assignee / Owner
- Filing Date
- 2024-03-15
- Publication Date
- 2026-08-04
Smart Images
Figure 00000000_0000_ABST
Abstract
Description
/ 27 Coupling system for use with a solar tracker, and clip for use with a solar tracker coupling assembly. Cross-reference to related orders.
[001] This application claims the benefit and priority of U.S. Provisional Patent Application Serial No. 63 / 453,462, filed March 20, 2023, the entire contents of which are incorporated herein by reference in their entirety. This application claims the benefit and priority of U.S. Provisional Patent Application Serial No. 63 / 468,412, filed May 23, 2023, the entire contents of which are incorporated herein by reference in their entirety. FUNDAMENTALS Technical Area
[002] The present description refers to solar power generation systems and, more particularly, to clamps and fastening systems for attaching solar modules to a support structure. Fundamentals of the Related Technique
[003] Solar cells and solar panels are most efficient in sunny conditions when oriented towards the sun at a specific angle. Many solar panel systems are designed in combination with solar trackers, which follow the sun's path across the sky from east to west to maximize the systems' power generation capabilities. The relatively low energy produced by a single solar cell requires the use of thousands of solar cells, arranged in an array, to generate energy of sufficient magnitude to be usable, for example, as part of a power grid. As a result, very large solar trackers have been developed, hundreds of meters long and including hundreds to thousands of individual solar modules that are mechanically coupled to support structures. Petition 870250083290, dated 09 / 16 / 2025, page 55 / 87 / 27
[004] Coupling the various solar modules to the support structure requires a significant number of clamps or other mechanisms, each requiring a significant number of fasteners, which increases the manufacturing cost of each mechanism. As can be seen, assembling each of these mechanisms and firmly tightening each fastener requires an enormous amount of time, contributing to increased costs and longer assembly time. The present description seeks to address the shortcomings of previous tracking systems. SUMMARY
[005] According to one aspect of the present description, a coupling system for use with a solar tracker includes a saddle that defines a U-shaped profile extending between a first end portion and a second opposite end portion, the saddle defining a channel having an open upper portion and extending through each of the first end portion and the second end portion, the channel configured to selectively receive a module rail of a solar module, in which a groove is defined through the first and second side surfaces adjacent to the first end portion, and a set of clips slidingly supported within the channel of the saddle, the set of clips including a clip having a generally U-shaped profile that is defined as a crown interposed between a pair of legs, each of the pairs of legs extending from the crown and terminating in a respective hook,wherein an upward-facing tab is arranged on each leg of the pair of legs, wherein the set of clips is configured to transition from an open first position to a closed second position, where an upward-facing tab of each leg of the pair of legs is received within the groove of the saddle and a hook of each leg of the pair of legs is received within a respective groove formed in the module rail to selectively couple the module rail to the saddle. Petition 870250083290, dated 09 / 16 / 2025, pp. 56 / 87 / 27
[006] In some respects, the crown of the clip assembly may define an arched profile that defines an apex that extends into a gap formed between the pair of legs.
[007] In certain aspects, each hook of the leg pair can define a channel configured to receive a portion of the module rail, whereby when the clip assembly is placed in the second closed position, the channel propels the module rail towards the saddle and inhibits the movement of the module rail relative to the saddle.
[008] In other respects, the saddle may include a defined cutout through the first and second side surfaces of the saddle and adjacent to the first end portion, the cutout extending in a transverse direction to a defined longitudinal axis through the first and second end portion and through a top surface of the saddle, wherein the cutout allows a top portion of the pair of clip legs to extend outward and extend beyond a respective first side surface and second side surface of the saddle.
[009] In certain aspects, the saddle cutout may extend away from the upper surface by a distance that allows a flap of each respective leg of the clip leg pair to extend beyond a first and second respective end surfaces of the saddle.
[0010] In some respects, the clip assembly may further include a pin operatively coupled to the clip and slidably supported within the saddle groove, the pin defining a pair of opposing flanges that inhibit movement of the pin in a direction transverse to a longitudinal axis defined through the first and second end portions of the saddle.
[0011] In other respects, the clip may define a pair of ears extending from each respective leg of the pair of legs extending in a direction away from the hooks, each ear of the pair of ears defining Petition 870250083290, dated 09 / 16 / 2025, p. 57 / 87 / 27 a hole for receiving the pin.
[0012] In some respects, when in the first open position, each leg of the pair of legs may be opened in an outward direction, where a distance between an upper portion of each leg of the pair of legs is greater than a crown length.
[0013] In certain aspects, when in the first open position, the first leg of the pair of legs may be parallel to the second leg of the pair of legs.
[0014] According to another aspect of the present description, a clip for use with a solar tracker coupling assembly includes a crown that defines an arched profile extending between a first end portion and a second opposite end portion, a pair of open legs that define a gap for receiving a module rail of a solar module, a first leg of the pair of open legs disposed on the first end portion and a second leg of the pair of open legs disposed on the second end portion, each leg of the pair of open legs extending from the crown and terminating in a hook that extends into the gap, wherein each leg of the pair of open legs defines an upward-facing flap that extends away from the gap and towards the hook, and a pair of ears, a first ear disposed on a first leg of the pair of legs and a second ear disposed on a second leg of the pair of open legs,where the first ear is parallel to the second ear.
[0015] In some respects, each hook of the open leg pair can define a channel for receiving a part of a module rail from a solar module.
[0016] In other respects, each ear of the pair of ears may have a hole set for receiving a stud.
[0017] In certain aspects, the clip may comprise a sheet Petition 870250083290, dated 09 / 16 / 2025, page 58 / 87 / 27 unitary sheet of material, in which the crown, the pair of open legs, the pair of ears and the flaps turned upwards are an integral part of the unitary sheet of material.
[0018] In some respects, the clip may be made of a resilient material.
[0019] According to another aspect of the present description, a coupling system for use with a solar tracker includes a saddle that defines a U-shaped profile extending between a first end portion and a second opposite end portion, an inner surface of the saddle that defines a channel with an open upper portion and extending through each of the first end portion and the second end portion, wherein the inner surface of the saddle defines a pair of pockets in which an inner dimension extending between the pair of pockets is greater than an inner dimension of the remaining portion of the channel, a set of clips slidingly supported within the channel of the saddle, the set of clips including a clip with a generally U-shaped profile that defines a crown interposed between a pair of legs, wherein a portion of each leg of the pair of legs is selectively received within a respective pocket of the pair of pockets,Each leg of the pair of legs includes an upward-facing flap, where the clip assembly is configured to transition from a first open position, in which each upward-facing flap is received within a respective pocket of the pair of pockets, to a second closed position, in which each upward-facing flap is positioned within the remaining portion of the channel having an internal dimension smaller than the internal dimension extending between the pair of pockets.
[0020] In certain aspects, the saddle may include a groove formed through the first lateral surface and the second lateral surface, the groove configured to selectively receive the upward-facing flap of the pair of legs when the clip assembly is placed in the second closed position.
[0021] In some respects, each leg of the pair of legs of the set Petition 870250083290, dated 09 / 16 / 2025, p. 59 / 87 / 27 of clips may end in a hook that extends into a gap formed between the pair of legs.
[0022] In other respects, each hook of the pair of legs can define a channel for receiving a module rail from a solar module.
[0023] In certain aspects, the crown can define an arched profile that extends between the pair of legs.
[0024] In some respects, the pair of legs may be open in a direction that extends from the crown. BRIEF DESCRIPTION OF THE DRAWINGS
[0025] Several aspects and features of the present description are described below with reference to the drawings, in which: Figure 1 is a perspective view of a coupling assembly supplied according to the present description, shown coupled to a module rail and a torque tube; Figure 2 is a perspective view of the coupling assembly in Figure 1; Figure 3 is a side elevation view of the coupling assembly of Figure 1, shown coupled to the module rail and torque tube; Figure 4 is a perspective view of a set of clips for use with the coupling assembly of Figure 1; Figure 5 is an elevation view of a clip from the set of clips in Figure 3 shown in a first open position; Figure 6 is an elevation view of the clip from Figure 5 shown in a second closed position; Figure 7 is a perspective view of the coupling assembly of Figure 1 shown with the clip assembly of Figure 4 in the first open position and the module rail of Figure 1 partially extended within the coupling assembly; Petition 870250083290, dated 09 / 16 / 2025, page 60 / 87 / 27 Figure 8 is a side view of the coupling assembly of Figure 1 shown with the clip assembly of Figure 4 in the first open position and the module rail of Figure 1 partially extended within the coupling assembly; Figure 9 is a perspective view of the coupling assembly of Figure 1 shown with the clip assembly of Figure 4 in the second closed position and the rail of the module of Figure 1 coupled to the coupling assembly; Figure 10 is a side view of the coupling assembly of Figure 1 shown with the clip assembly of Figure 3 in the second closed state and the rail of the module of Figure 1 coupled to the coupling assembly; Figure 11 is a perspective view of another embodiment of a coupling assembly provided according to the present description.
[0026] Figure 12 illustrates another embodiment of a coupling assembly provided according to the present description, where one or more sets of clips are integrated into the saddle component. More specifically, Figure 12 is a perspective view of the integrated saddle and clip component coupled to a torque tube by means of a strip assembly and uncoupled from a module rail.
[0027] Figure 13 is a perspective view of the integrated saddle and clip component coupled to the torque tube via the strip assembly and coupled to the module rail via one or more integral clip assemblies on the integrated saddle and clip component.
[0028] Figure 14 is a side elevation view of the integrated saddle and clip component, shown in Figure 13, coupled to the torque tube by means of the strip assembly and coupled to the module rail by means of one or more sets of clips integral to the integrated saddle and clip component.
[0029] Figure 15 is a perspective view of the saddle component. Petition 870250083290, dated 09 / 16 / 2025, pages 61 / 87 / 27 and clip integrated separately. DETAILED DESCRIPTION
[0030] The present description is directed to a coupling assembly for use with a solar tracker. The coupling assembly described herein reduces the number of fasteners required to couple solar modules to a torque tube and reduces the amount of labor required to install and / or adjust solar modules on torque tubes. The coupling assembly includes a saddle, a pair of clip assemblies slidably supported by the saddle, and a strip assembly rotatably supported by the pair of clip assemblies. The saddle is configured to be selectively coupled to a torque tube of a solar tracker via the strip assembly and is configured to be selectively coupled to a module rail, such as an FSLR 7 series (S7) of a solar tracker photovoltaic module via the pair of clip assemblies 50 to allow mounting of the solar modules on the torque tube.Although generally described as being used with an S7 module rail, the coupling assembly is anticipated to be usable with any suitable solar module rail, such as a FSLR series 6, among others.
[0031] The saddle defines a generally U-shaped profile, defining a channel for receiving a module rail. A lower surface of the saddle defines a pair of protrusions arranged at spaced intervals from each other. In this way, the pair of protrusions defines a gap for receiving a torque tube from the solar tracker. The saddle defines a pair of slots through opposite lateral surfaces adjacent to a respective protrusion of the pair of protrusions. The pair of slots is oriented in the vertical direction (e.g., transverse to a longitudinal axis defined through the first and second opposite end portions of the saddle). The pair of slots is configured to receive a corresponding pin from a set of clips. Petition 870250083290, dated 09 / 16 / 2025, p. 62 / 87 / 27
[0032] The clip assembly includes a clip and a pin operably coupled to the clip. The clip defines a generally U-shaped profile with a crown interposed between a pair of open legs. Although generally described as being open, it is provided that the pair of legs may define any suitable arrangement, including parallel, without departing from the scope of the present description. The crown defines an arched profile that extends between the pair of open legs, although it is provided that the crown may define any suitable profile, such as linear, curvilinear, combinations thereof, among others. Each pair of open legs terminates in a hook that extends within a gap formed between the pair of open legs and extends towards the crown. Each of the hooks is configured to be received within a respective groove formed within the module rail and defines a channel for selective receipt of a portion of the module rail.In this way, as the set of clips moves from an open first position to a closed second position, the hooks are received within the respective grooves of the module rail and propel the module rail towards the saddle to selectively couple the module rail to the saddle.
[0033] Each of the open legs defines an upward-facing flange that is configured to be received within a respective groove of the saddle when the clip assembly is placed in the second closed position. As can be observed, the upward-facing flanges abut or contact an outer perimeter of the groove to inhibit movement of the module rail in the vertical or longitudinal direction. It is foreseen that an external force can be applied to the upward-facing flanges to release them from the saddle grooves and allow adjustment or removal of the module rail relative to the saddle. An lug is disposed on each of the open legs that extend away from the hooks. The lugs are arranged in a parallel relationship and define a hole for receiving a pin from the assembly. Petition 870250083290, dated 09 / 16 / 2025, page 63 / 87 / 27 clips for sliding the clip assembly to the saddle. It is foreseen that the clip of the clip assembly can be formed from a single piece of sheet material or similar, and each of the hooks, upturned tabs, ears, can be formed from the single piece of sheet material using any suitable method, such as stamping, forming, bending, combinations thereof, among others. As can be recognized, it is foreseen that the clip can be formed from any suitable number of components and can be formed using any suitable method without departing from the scope of the present description.
[0034] The pin defines a generally linear central portion that extends between a pair of radial flanges. An external dimension of the pair of radial flanges is larger than an external dimension of the linear central portion and larger than an internal dimension of the saddle grooves. In this way, the linear central portion is configured to be received within the holes of the clip lugs and within the saddle grooves, and the pair of radial flanges prevents the pin from being removed from the saddle.
[0035] The strap assembly includes a pair of straps, a T-bolt, a cylinder, and a nut. The pair of straps each defines a generally lazy “L” shaped profile that extends between a pair of eyelets. The first eyelet is configured to receive the pin to rotatably support the strap on the saddle. The second eyelet of a first strap is configured to receive a portion of the T-bolt, and the second eyelet of a second strap is configured to receive the barrel, which in turn includes a hole to slide a portion of the T-bolt into place. The pair of straps cooperate to define a gap for receiving the torque tube. The strap assembly is configured to transition from a first open position, where the torque tube is free to move relative to the saddle, to a second closed position, where the torque tube is secured or otherwise coupled to the saddle, by rotating the nut in a first direction to pull the second eyelet. Petition 870250083290, dated 09 / 16 / 2025, p. 64 / 87 / 27 of the strips towards each other. As can be observed, rotating the nut in the first direction causes the first eyelet of each strip to pull or somehow attract the pins of the clip assemblies towards the torque tube. Continued rotation of the nut in the first direction causes the hooks of the clip assembly legs to be received within the grooves of the module rail and pull the module rail towards the saddle until the upward-facing tabs are received within the saddle grooves. Further rotation of the nut in the first direction will lock or inhibit the movement of the module rail and torque tube relative to the saddle.
[0036] It is foreseen that the saddle may have cutouts adjacent to each end portion and extending across opposite side surfaces. The cutouts allow an upper portion of each leg of the clip assembly, including the upward-facing tabs, to extend outward and overtake the opposite side surfaces of the saddle. The cutouts provide a surface on which the upward-facing tabs can rest and cause the legs to compress or move from the first open position to the second closed position. In some embodiments, instead of cutouts, the saddle may include a pair of pockets defined on an inner surface of the channel. An inner dimension extending between the pair of pockets is larger than an inner dimension of the remaining portion of the channel, so that the upper portion of each leg of the clip assembly, including the upward-facing tabs, can extend outward and be received within the pockets.The pair of pockets defines a protrusion that touches or comes into contact with the upward-facing flaps to cause the legs to compress or transition from the first open position to the second closed position. As can be observed, the pair of pockets protects the clip assemblies or prevents external objects from coming into contact with and damaging the clip assemblies. These and other aspects of the present description will be described in detail below with reference to the drawings. Petition 870250083290, dated 09 / 16 / 2025, pp. 65 / 87 / 27
[0037] Referring now to the drawings, Figures 1-3 illustrate a coupling assembly generally identified by reference number 10. The coupling assembly 10 includes a saddle 12, a pair of clip assemblies 50, and a strip assembly 82. As will be described in more detail below, the saddle 12 is configured to be selectively coupled to a torque tube 100 of a solar tracker (not shown) by means of the strip assembly 82 and is configured to be selectively coupled to a module rail 110, such as a FSLR series 7 (S7) of a photovoltaic solar module (not shown) of the solar tracker by means of the pair of clip assemblies 50 to allow the mounting of the solar modules on the torque tubes 100. Although generally described as being configured for use with S7 modules, it is anticipated that the coupling assembly 10 can be configured for use with any suitable solar module, such as FSLR series 6 modules, among others.
[0038] With continuous reference to Figures 1-3, saddle 12 defines a generally saddle-type configuration, defining a longitudinal axis AA extending between a first end portion 14 and a second opposite end portion 16. Saddle 12 is foreseen to include any suitable length (e.g., dimension extending along the longitudinal axis AA between the first and second end portions 14, 16), depending on the design requirements of the coupling assembly 10. Saddle 12 includes a first side surface 18 and a second opposite side surface 20 extending between each of the first and second end portions 14, 16 and a bottom surface 22 extending between each of the first and second end portions 14, 16 and the first and second side surfaces 18, 20.A pair of protrusions 24 is arranged on the lower surface 22 extending in a downward direction (for example, in the same direction as the lower surface 22 is facing). The pair of protrusions 24 is arranged in relation to... Petition 870250083290, dated 09 / 16 / 2025, p. 66 / 87 / 27 spaced apart from each other along the longitudinal axis AA and defines a gap 26 between them which is configured to receive a portion of a torque tube 100 in the same. In this way, when coupled to the coupling assembly 10, the torque tube 100 extends transversely to the longitudinal axis AA.
[0039] Saddle 12 includes an inner surface 28 that defines a cavity 30 therein and extends toward the lower surface 22. The cavity 30 includes an inner shape that is generally complementary to the profile of the lower surface 22. In this way, the inner surface 28 defines a generally flat surface 32 adjacent to each of the first and second end portions 14, 16 that is configured to support or otherwise abut a portion of the module rail 110 of the solar module when the module rail 110 is seated within a portion of the cavity 30 (Figures 9 and 10). Saddle 12 includes a pair of cutouts or reliefs 34 defined through the first and second side surfaces 18, 20 of saddle 12 adjacent to each of the first and second end portions 14, 16.The pair of cutouts 34 is configured to provide clearance or allow the legs of the clip assemblies 50 to be placed in a first open position (e.g., projecting beyond or spreading beyond each of the first and second side surfaces 18, 20 (Figure 8)). An upper portion of each of the first and second side surfaces 18, 20 defines a respective outward-facing flange 36. The outward-facing flanges 36 extend transversely to the longitudinal axis AA and in a direction away from the first and second side surfaces 18, 20 (e.g., away from the cavity 30). Each of the outward-facing flanges 36 defines a generally flat upper surface 38 that is configured to abut or otherwise support a solar module when the solar module rail 110 is coupled to the coupling assembly 10. In some embodiments, one or both of the outward-facing flanges 36 may include a... Petition 870250083290, dated 09 / 16 / 2025, page 67 / 87 / 27 downward-facing tab or ear 40 extending towards the lower surface 22 and spaced relative to the respective first and second side surfaces 18, 20. Although generally illustrated as extending a portion of the length of the outward-facing flanges 36 (e.g., along the longitudinal axis AA), it is provided that one or both downward-facing tabs 40 may extend for any length of the outward-facing flanges 36, may have different lengths, or may be arranged in different locations along the longitudinal axis AA without departing from the scope of the present description. As can be observed, the downward-facing tabs 40 increase the stiffness or increase the bending resistance of the saddle 12.
[0040] With continuous reference to Figures 1-3, saddle 12 includes a pair of grooves 42 extending through the first and second side surfaces 18, 20 and disposed adjacent to each of the pairs of cutouts 34. Although generally illustrated as being disposed over the pair of protrusions 24, it is contemplated that the pair of grooves 42 may be disposed at any location along the length of the pair of cutouts 34 (e.g., along the longitudinal axis AA). In a non-limiting embodiment, the pair of grooves 42 is disposed 200 mm apart from each other. Each groove of the pair of grooves 42 extends in a direction transverse to the longitudinal axis AA (e.g., in a direction from the lower surface 22 towards the upper surface 38 of the outward-facing flanges) and is configured to slidely retain a respective pin of the pin pair 76 of the clip assembly 50.Although generally described as being oriented in a vertical or transverse direction to the longitudinal axis AA, it is contemplated that one or both pairs of grooves 42 may extend in any suitable direction, such as diagonal, horizontal, among others, without departing from the scope of the present description. As can be recognized, it is foreseen that saddle 12 may include any number of grooves 42 arranged through the first and. Petition 870250083290, dated 09 / 16 / 2025, page 68 / 87 / 27 second lateral surfaces 18, 20 without departing from the scope of the present description.
[0041] Continuing with Figures 1-3, and with further reference to Figures 4-6, the clip assembly 50 includes a clip 52 and a pin 76 rotatably coupled to clip 52. Clip 52 is configured to be transferred from a first open configuration (Figure 5) to a second closed or fixed configuration (Figure 6) and defines a generally U-shaped profile having a crown 54 interposed between a pair of legs 56. When placed in the first open configuration (Figure 5), the crown 54 defines a generally arched profile as it extends between a first end portion 58 and a second opposite end portion 60. In this way, a central portion of the crown 54 defines an apex 62, which, as can be observed, causes the crown 54 to act as a polarizing element, as will be described in more detail below.The S7 110 photovoltaic module rail consists of a sheet metal structure with various holes and slots. The mounting features of the S7 110 module rail are a quick or snap-fit between the 110 module rail and the tracker rail without using any conventional or permanent fastening method. 112 through slots are provided at 200 mm and 500 mm intervals from a central portion of the 110 module rail. It is anticipated that two 110 slots or all four 110 slots can be used for rail mounting purposes.
[0042] A first leg of the pair of legs 56 is coupled to the first end portion 58 of the crown 54, and the second leg of the pair of legs 56 is coupled to the second end portion 60 of the crown 54. In this way, the pair of legs 56 is arranged in a mirrored configuration around the apex 62 of the crown 54. Each leg of the pair of legs 56 is substantially similar to the other, and therefore only one leg 56 will be described in detail here for the sake of brevity. Leg 56 is coupled to and extends from the first end portion 58 of the crown 54 and terminates in a Petition 870250083290, dated 09 / 16 / 2025, p. 69 / 87 / 27 hook or J-shaped configuration 64. In this way, the hook 64 curves and extends backwards towards the crown 54, defining a channel 66 for receiving a portion of the rail of module 110, as will be described in more detail below. When clip 52 is placed in the first open position, leg 56 is opened outwards (e.g., away from the apex 62 of crown 54) and defines an angle generally orthogonal to the first end portion 58 of crown 54, although it is provided that leg 56 may define any suitable angle with respect to crown 54. As can be observed, by being opened outwards, the hook 64 of each leg of the pair of legs 56 is further apart from each other than a portion of each leg of the pair of legs 56 adjacent to crown 54, which allows a portion of the track of module 110 to be advanced between a gap 68 defined between the pair of legs 56 (Figures 7 and 8).
[0043] Leg 56 defines a flap 70 that extends horizontally in a direction towards the hook 64 and away from the apex 62 of the crown 54. The flap 70 is disposed on leg 56 in a location where, when in the first open position, the flap is located above and, in some embodiments, rests on a portion of the saddle protrusion 34 and, when in the second closed or fastened position, is received within a respective groove of the pair of grooves 42 to lock or otherwise inhibit the movement of the clip assembly 50 relative to the saddle 12, as will be described in more detail below. Leg 56 includes an ear 72 that extends from the first end portion 58 of the crown 54 in a direction that is away from the hook 64. When the clip assembly 50 is in the first open position, ear 72 is oriented in a vertical direction where the respective ears 72 of the pair of legs 56 are parallel to each other.Ear 72 includes a hole 74 defined through it to receive pin 76, which attaches clip 52 and strap assembly 82 to saddle 12 by means of a respective groove of the pair of grooves 42.
[0044] Clip 52 is expected to be made of any material. Petition 870250083290, dated 09 / 16 / 2025, pp. 70 / 87 / 27 suitable resilient material, such as a metal, a polymer, a composite, among others. In a non-limiting embodiment, clip 52 is formed from a resilient sheet material, such as galvanized steel. Clip 52 is formed from a single piece of material that is worked or otherwise machined to reduce the amount of material and processes required to form clip 52 than if the clip were formed from several pieces of material joined together using fasteners, welding, adhesives, among others. As can be recognized, clip 52 can be formed using any suitable number of components and by any suitable methods without departing from the scope of the present material.
[0045] Pin 76 defines a generally bar-type configuration having a linear center portion 78 interposed between a pair of flanges 80. The linear center portion 78 includes an external dimension that is configured to be received within the hole 74 of the ear 72 and a corresponding groove of the saddle groove pair 42 to slide support the pin 76. Each flange of the flange pair 80 includes an external dimension that is larger than the external dimension of the linear center portion 78 and larger than the internal dimension of the groove 42 to keep the pin 76 within the groove 42.
[0046] Referring again to Figures 1-3 and with further reference to Figure 9, the strip assembly 82 includes a pair of strips 84, a T-bolt 86, a cylinder 88, and a nut 90. Each strip of the pair of strips 84 is substantially similar to the others, and therefore only one strip 84 will be described in detail here for the sake of brevity. Strip 84 defines a generally lazy “L” shaped profile extending to a first end portion 92 (Figure 3) and a second opposite end portion 94. Each of the first and second end portions 92, 94 defines an eyelet or loop 96 to receive the pin 76 adjacent to the first end portion 92 and to receive one of the T-bolts 86 or the barrel 88 adjacent to the second end portion 94 (Figures 3 and 4). As it may be Petition 870250083290, dated 09 / 16 / 2025, p. 71 / 87 / 27 observed, the loop 96 adjacent to the first end portion 92 is rotationally supported on pin 76 to allow rotational movement of the strip pair 84 relative to the saddle 12 to accommodate the movement or insertion of the torque tube 14 between the strip pair 84. In this way, the first end portion 92 of the strip 84 is received within an opening 98 (Figure 3) defined by a respective protrusion of the protrusion pair 24 of the saddle 12. The barrel 88 receives a portion of the T-screw 86 sliding through it, and the T-screw 86 threaded engages with the nut 90. In this way, rotating the nut 90 in a first direction causes the second end portions 94 of each respective strip of the strip pair 84 to be pulled towards each other to fasten or otherwise secure the torque tube 14 to the saddle. 12.Rotating the nut 90 in a second opposite direction allows the second end portions 94 of the pair of strips 84 to expand or allow the torque tube 14 to move relative to the saddle 12. Although generally described as using a T-bolt 88 and a nut 90, it is anticipated that any suitable components capable of fastening or otherwise securing the torque tube 14 to the saddle 12 may be used without departing from the scope of the present description.
[0047] With reference to Figures 7-10, in operation, the clip assembly 50 and the strip assembly 82 are placed in the first open position (Figures 7 and 8) so that the pair of legs 56 of clip 52 is open outwards. In this first position, the pair of tabs 70 of clip 52 is positioned above the saddle protrusion 34. The module rail 110 is advanced towards the saddle 12 and received within the gap 68 defined by the pair of legs 56 of clip 52 until a portion of the module rail 110 touches the apex 62 of the crown 54 (Figure 8). The continuous advancement of the module rail 110 towards the saddle 12 propels the clip assembly 50 towards the saddle 12 and causes the pair of tabs 70 to abut the inner surface 28 of the saddle 12, causing the hooks 64 to be received within a corresponding groove 112. Petition 870250083290, dated 09 / 16 / 2025, page 72 / 87 / 27 formed within the rail of module 110. The additional advancement of the rail of module 110 towards saddle 12 causes the tabs 70 to be received within a respective groove of the pair of grooves 42 of saddle 12 to lock the rail of module 110 to saddle 12 (Figures 9 and 10). As can be observed, portions of the rail of module 110 are received within a respective channel 66 of the pair of legs 56 to couple or otherwise fix the support rail to the saddle. In this way, the hooks 64 and tabs 70 of the clip assembly 50 cooperate to inhibit the vertical or torsional movement of the module rail 110 in relation to the saddle 12. With the module rail 110 coupled to the saddle 12, the nut 90 of the strap assembly 82 is turned in the first direction to cause the pair of straps 84 to be pulled towards each other.The continuous rotation of nut 90 in the first direction causes the pair of straps 84 to tighten or otherwise secure the torque tube 14 and causes the pair of straps 84 to pull the pair of pins 76 and therefore the clip assembly 50 towards the torque tube 14 to further secure the rail of module 110 to the saddle 12, while at the same time securing the torque tube 14 to the saddle 12 and inhibiting the movement of the rail of module 110 and the torque tube 14 relative to the saddle 12. It is foreseen that, once the rail of module 110 is received within the gap 68 formed between the pair of legs 56 of the clip assembly 50, nut 90 of the strap assembly 82 can be rotated in the first direction to cause the pair of legs 84 to pull the pair of pins 76 and therefore the clip 52 towards the saddle 12 without the need to provide an external force on the rail of module 110.As can be seen, the continuous rotation of nut 90 in the first direction causes module rail 110 and torque tube 14 to be simultaneously fixed to saddle 12.
[0048] Although generally described as being initially placed in the first open position, it is anticipated that the set of clips 50 may initially be placed in the second closed position. In this way, as the rail of module 110 advances towards saddle 12, parts of Petition 870250083290, dated 09 / 16 / 2025, p. 73 / 87 / 27 The rail of module 110 touches or comes into contact with the hooks 64 of the pair of legs 56 of the clip assembly 50. The continuous advance of the rail of module 110 towards the saddle 12 causes the pair of legs 56 to open outwards and allows the rail of module 110 to be received within the gap 68 formed between the pair of legs 56. At this point, the procedure described above can be followed to fix the rail of module 110 and the torque tube 14 to the saddle 12.
[0049] It is foreseen that the tabs 70 can be pressed using an external force to allow the support rail to be removed from the saddle 12. In this way, an external force is applied to each of the tabs 70 (incrementally or sequentially) to disengage the tabs 70 from the grooves 42 while driving the module rail 110 in a direction away from the saddle 12. As the tabs 70 are pressed and therefore disengaged from the grooves 42, the clip assembly 50 and the module rail 110 can be moved away from the saddle 12 and release the module rail 110 from the clip assembly 50. It is foreseen that this process can be used to completely remove the module rail 110 or to allow adjustments of the position of the module rail 110 relative to the saddle 12.
[0050] Returning to Figure 11, another embodiment of a coupling assembly is illustrated and generally identified by the reference numeral 200. The coupling assembly 200 is substantially the same as the coupling assembly 10, and therefore only the differences between them will be described in detail here for the sake of brevity. The saddle 212 of the coupling assembly 200 does not include the pair of cutouts 34, and instead, the first and second side surfaces 218, 220 extend to the first and second end portions 214, 216. A first pair of pockets 260 is formed adjacent to the first end portion 214, and a second pair of pockets 270 is formed adjacent to the second end portion 216. The first and second pair of pockets 260, 270 are Petition 870250083290, dated 09 / 16 / 2025, pp. 74 / 87 / 27 substantially similar to each other and, therefore, only the first pair of pockets 260 will be described in detail here for the sake of brevity.
[0051] The first pair of pockets 260 defines a generally U-shaped depression formed within the inner surface 228 and extending away from each other so that the distance between each pocket of the first pair of pockets 260 is greater than one dimension between the inner surface adjacent to each of the first and second side surfaces 218, 220. Each pocket of the first pair of pockets 260 extends through the upper surface 238 and extends towards the protrusion 224 and ends in a projection 262 that transitions the pocket of the first pair of pockets 260 to the inner surface 228. As can be observed, the first pair of pockets 260 provides space for the pair of legs 56 of the clip assembly 50 to be placed in the first position, open or apart. The protrusion 262 provides a surface against which the tabs 70 of the clip assembly 50 rest to initially hold the clip assembly 50 in the first open position.The coupling assembly 200 operates in a substantially similar manner to the coupling assembly 10, and therefore, the operation of the coupling assembly 200 will not be described in detail here for the sake of brevity.
[0052] Figures 12-15 illustrate another embodiment of a coupling assembly 300 provided according to the present description. The coupling assembly 300 may be similar to or the same as the coupling assembly 10, as described elsewhere in this document, except where otherwise described herein. In particular, the coupling assembly 300 includes one or more clip assemblies 350 that are integrated into the saddle component 312. Figure 12 is a perspective view of the integrated saddle and clip component 312 coupled to the torque tube 100 by means of the strip assembly 82 and uncoupled from a module rail 110, while Figure 13 is a perspective view of the component Petition 870250083290, dated 09 / 16 / 2025, page 75 / 87 / 27 integrated saddle and clip component 312 coupled to torque tube 100 by means of strip assembly 82 and coupled to module rail 110 by means of one or more integral clip assemblies 350 in the integrated saddle and clip component 312. Figure 14 is a side elevation view of the integrated saddle and clip component 312, shown in Figure 13, coupled to torque tube 100 by means of strip assembly 82 and coupled to module rail 110 by means of one or more integral clip assemblies 350 in the integrated saddle and clip component 312. Figure 15 is a perspective view of the integrated saddle and clip component 312 in isolation.
[0053] The coupling assembly 300 may include the integrated saddle and clip component 312 and the strap assembly 82. One or more clip assemblies 350 may be integrally formed with the body of the saddle component to form a single integrated saddle and clip workpiece component 312 (for example, so that one or more clip assemblies 350 integrally formed with the body of the saddle component are movable relative to a body of the saddle portion of the integrated saddle and clip component 312). The strap assembly 82 may be coupled to the integrated saddle and clip component 312.For example, as shown here for the illustrated embodiment of the integrated saddle and clip component 312, the strip assembly 82 can be coupled to the integrated saddle and clip component 312 on the portion of the pair of clip assemblies 350 of the integrated saddle and clip component 312 (for example, so that, as illustrated, the strip assembly 82 has one end of the strip 84 coupled to a first clip assembly 350a on the integrated saddle and clip component 312 and the opposite end of the strip 84 coupled to a second clip assembly 350b on the integrated saddle and clip component 312). As will be described in more detail elsewhere in this document, the saddle portion of the integrated saddle and clip component 312 can be configured to be selectively coupled to the torque tube 100 of a solar tracker (not shown) by means of the assembly of. Petition 870250083290, dated 09 / 16 / 2025, page 76 / 87 / 27 strips 82, and the portion of one or more clip assemblies 350 (for example, a pair of clip assemblies 350) of the integrated saddle and clip component 312 can be configured to be selectively coupled to the module rail 110, as a FSLR series 7 (S7) of a photovoltaic solar module (not shown) of the solar tracker by means of the clip assembly portion 350 of the integrated saddle and clip component 312 to allow the mounting of solar modules on torque tubes 100 (for example, by means of coupling one or more solar modules to the module rail 110).
[0054] A body of the saddle portion of the integrated saddle and clip component 312 can be seen in Figure 15. The saddle portion of the integrated saddle and clip component 312 may include an inner surface 28 defining a cavity 30 therein and extending towards the lower surface 22. The cavity 30 may include an inner shape that is generally complementary to the profile of the lower surface 22. In this way, the inner surface 28 may define a generally flat surface 32 adjacent to each of the first and second end portions 14, 16 which is configured to support or otherwise abut a portion of the module rail 110 of the solar module when the module rail 110 is seated within a portion of the cavity 30.The saddle portion of the integrated saddle and clip component 312 may include a pair of cutouts or reliefs 34 defined through the first and second side surfaces 18, 20 of the saddle portion adjacent to each of the first and second end portions 14, 16. The pair of cutouts 34 may be adjacent to the location of the pair of clip assemblies 350 on the body of the integrated saddle and clip component 312. The pair of cutouts 34 may be configured to provide a relative motion function for the pair of clip assemblies 350 with respect to the saddle portion. For example, the cutouts 34 may be configured to allow the clip assemblies to flex or rotate relative to the flat surface 32 of the saddle portion.
[0055] The integrated saddle and clip component 312 may include a Petition 870250083290, dated 16 / 09 / 2025, p. 77 / 87 / 27 or more pairs of grooves 42 extending through the first and second side surfaces 18, 20. The pair of grooves 42 may be set in each of the pairs of clip assemblies 350, and the pair of grooves 42 may be arranged adjacent to each of the pairs of cutouts 34. In a non-limiting embodiment, the pair of grooves 42 is arranged 200 mm apart from each other in a direction along the longitudinal axis of the integrated saddle and clip component 312 (e.g., spaced 200 mm along a distance traversing a longitudinal length of side surface 18 or 20).Each groove of the pair of grooves 42 can be configured to slide retain a respective pin of the clip assembly 50, so that a pin can extend through a groove 42 on one side of the clip assembly 350, through the strip 84 positioned in the clip assembly 350 between opposite sides of the clip assembly, and into the other groove 42 of the pair on the opposite side of the clip assembly 350, so that the pin can act to engage the strip 84 to the clip assembly 350. As can be recognized, it is provided that the saddle can include any number of grooves 42 arranged through the first and second side surfaces 18, 20 without departing from the scope of the present description.
[0056] The clip assembly 350 may include a pin (e.g., pin 76, as shown elsewhere herein) and a clip 352.Clip 352 can be configured to be transferred from a first open configuration (e.g., Figure 12) to a second closed or fixed configuration (e.g., Figures 13, 14) and can define a generally U-shaped profile having a crown 354 interposed between a pair of legs 356. When placed in the first open configuration, the crown 354 can define a generally arched profile when it extends between a first end portion and a second opposite end portion. In this way, a central portion of the crown 354 can define an apex 62, which, as can be observed, when present, can cause the crown 354 to act as a polarizing element. Each clip 352 can include a groove for... Petition 870250083290, dated 09 / 16 / 2025, page 78 / 87 / 27 strip 353, for example, located between the pair of legs 356, as in the crown 354 between the pair of legs 356. The mounting features of the S7 110 module rail can be a quick or fast snap-fit between the 110 module rail and the tracker rail without using any conventional or permanent fastening method.
[0057] A first leg of the pair of legs 356 can be coupled to a first end portion of the crown 354 and the second leg of the pair of legs 356 can be coupled to a second opposite end portion of the crown 354. In this way, the pair of legs 356 can be arranged in a mirrored configuration around the crown 354. Each leg 356 can extend outward from the crown 354 and terminate in a hook or J-shaped configuration 364. In this way, the hook 364 can curve and extend backward toward the crown 354 to set the channel 66 to receive a portion of the module rail 110, as described elsewhere in this document. When the clip 352 is placed in the first open position, the leg 356 can be opened outward (e.g., away from the crown 354).As can be seen, when opened outwards, the hook 364 of each leg of the pair of legs 356 can be further apart from each other than a portion of each leg of the pair of legs 356 adjacent to crown 54, which allows a portion of the rail of module 110 to be advanced between a defined gap between the pair of legs 356.
[0058] The clip 352 can be formed from any suitable resilient material, such as a metal, a polymer, a composite, among others. In a non-limiting embodiment, the clip 52 is formed from the same material as the saddle component of the integrated saddle and clip component 312, so that the saddle portion and the clip portion 352 of the integrated saddle and clip component 312 are formed as a single piece of material. The strip assembly 82 may be similar to or the same as the strip assembly 82 described elsewhere in this document, for example, so that the strip assembly Petition 870250083290, dated 09 / 16 / 2025, pp. 79 / 87 / 27, may include strip 84. For example, herein strip 84 may be a single strip 84 component configured to extend from one side of the integrated saddle and clip component 312 (e.g., from the strip groove 353 in a clip assembly 352a on an end portion of the integrated saddle and clip component 312), around the torque tube 100 and to the other side of the integrated saddle and clip component 312 (e.g., to the strip groove 353 in another clip assembly 352b on an opposite end portion of the integrated saddle and clip component 312).
[0059] In operation, one or more sets of clips 350 and the set of strips 82 can be placed in the first open position (e.g., Figure 12), for example, so that the pair of legs 356 of clip 352 is in a first orientation relative to the flat surface 32 on the saddle portion of the integrated saddle and clip component 312 (e.g., the pair of legs is open outwards and / or in a first inclined angular orientation relative to the flat surface 32). The rail of module 110 can be advanced towards the saddle portion (e.g., advanced towards the flat surface 32) and received within the gap defined between the pair of legs 356 of clip 352 until a portion of the rail of module 110 touches the crown 354.The continuous advancement of the module rail 110 towards the saddle portion can act to propel the clip assembly 350 towards the saddle portion (e.g., towards the flat surface 32) and cause the hooks 364 to be received within a corresponding groove 112 formed within the module rail 110. As can be observed, portions of the module rail 110 can be received within a respective channel of the leg pair 356 to couple or otherwise fix the support rail to the saddle portion of the integrated saddle and clip component 312. In this way, the hooks 364 of the clip assembly 350 can cooperate to inhibit the vertical or torsional movement of the module rail 110 relative to the saddle portion of the integrated saddle and clip component 312. With the module rail. Petition 870250083290, dated 09 / 16 / 2025, pages 80 / 87 / 27 110 coupled to the saddle portion, the strip assembly 82 can be actuated to tighten the strip assembly 82 around the torque tube 100 to further secure the module rail 110 to the saddle portion of the integrated saddle and clip component 312, while at the same time securing the torque tube 100 to the integrated saddle and clip component 312 and helping to inhibit movement of the module rail 110 and the torque tube 100 relative to the saddle portion (e.g., relative to the flat surface 32) of the integrated saddle and clip component 312.
[0060] Although various forms of description have been shown in the drawings, the description is not intended to be limited to them, as it is intended that the description have a scope as broad as the technique allows and that the specification be read in the same way. Therefore, the description above should not be interpreted as limiting, but merely as examples of particular forms. Petition 870250083290, dated 09 / 16 / 2025, pp. 81 / 87
Claims
1 / 5 CLAIMS 1. Coupling system for use with a solar tracker, characterized in that it comprises: a saddle defining a U-shaped profile extending between a first end portion and a second opposite end portion, the saddle defining a channel having an open upper portion and extending through each of the first end portion and the second end portion, the channel configured to selectively receive a module rail of a solar module, in which a groove is defined through the first and second side surfaces adjacent to the first end portion;and a set of clips supported in a sliding manner within the saddle channel, the set of clips including a clip with a generally U-shaped profile that defines a crown interposed between a pair of legs, each of the pairs of legs extending from the crown and ending in a respective hook, wherein an upward-facing tab is disposed on each leg of the pair of legs, wherein the set of clips is configured to transition from a first open position to a second closed position, wherein an upward-facing tab of each leg of the pair of legs is received within the saddle groove and a hook of each leg of the pair of legs is received within a respective groove formed in the module rail to selectively couple the module rail to the saddle.
2. Coupling system according to claim 1, characterized in that the crown of the clip assembly defines an arched profile that defines an apex that extends into a gap formed between the pair of legs.
3. Coupling system according to claim 1, characterized in that each hook of the leg pair defines a channel configured to receive a portion of the module rail, wherein when the clip assembly is placed in the second closed position, the channel propels the module rail towards the saddle and inhibits the movement of the module rail relative to the saddle.
4. Coupling system according to claim 1, characterized in that the saddle includes a cutout defined through the first and second side surfaces of the saddle and adjacent to the first end portion, the cutout extending in a transverse direction to a longitudinal axis defined through the first and second end portions and through an upper surface of the saddle, wherein the cutout allows an upper portion of the pair of clip legs to extend outwards and extend beyond a respective first side surface and second side surface of the saddle.
5. Coupling system according to claim 4, characterized in that the saddle cutout extends away from the upper surface to a distance that allows a tab of each respective leg of the clip leg pair to extend beyond a first and second respective end surfaces of the saddle.
6. Coupling system according to claim 1, characterized in that the clip assembly additionally includes a pin operatively coupled to the clip and slidably supported within the saddle groove, the pin defining a pair of opposing flanges that inhibit movement of the pin in a direction transverse to a longitudinal axis defined through the first and second end portions of the saddle.
7. Coupling system according to claim 6, characterized in that the clip defines a pair of ears extending from each respective leg of the pair of legs extending in a direction away from the hooks, each ear of the pair of ears defining a hole for receiving the pin.
8. Coupling system according to claim 1, Petition 870250083290, dated 09 / 16 / 2025, page 83 / 87 3 / 5 characterized in that, when in the first open position, each leg of the pair of legs is opened in an outward direction where a distance between an upper portion of each leg of the pair of legs is greater than a crown length.
9. Coupling system according to claim 1, characterized in that, when in the first open position, the first leg of the pair of legs is parallel to the second leg of the pair of legs.
10. Clip for use with a solar tracker coupling assembly, characterized in that it comprises: a crown defining an arched profile extending between a first end portion and a second opposite end portion; a pair of open legs defining a gap for receiving a module rail of a solar module, a first leg of the pair of open legs disposed at the first end portion and a second leg of the pair of open legs disposed at the second end portion, each leg of the pair of open legs extending from the crown and terminating in a hook extending into the gap, wherein each leg of the pair of open legs defines an upward-facing tab extending away from the gap and towards the hook;and a pair of ears, a first ear situated on a first leg of the pair of open legs and a second ear situated on a second leg of the pair of open legs, wherein the first ear is parallel to the second ear.
11. Clip according to claim 10, characterized in that each hook of the open leg pair defines a channel for receiving a portion of a module rail of a solar module.
12. Clip according to claim 10, characterized in that each ear of the pair of ears defines a hole for receiving a pin.
13. Clip according to claim 10, characterized in that the clip comprises a single sheet of material, wherein the crown, the pair of open legs, the pair of ears and the upward-facing tabs are integral parts of the single sheet of material.
14. Clip according to claim 10, characterized in that the clip is formed of a resilient material.
15. Coupling system for use with a solar tracker, characterized in that it comprises: a saddle defining a U-shaped profile extending between a first end portion and a second opposite end portion, an inner surface of the saddle defining a channel having an open upper portion and extending through each of the first end portion and the second end portion, wherein the inner surface of the saddle defines a pair of pockets where an inner dimension extending between the pair of pockets is greater than an inner dimension of the remaining portion of the channel;and a set of clips supported in a sliding manner within the saddle channel, the set of clips including a clip with a generally U-shaped profile that defines a crown interposed between a pair of legs, wherein a portion of each leg of the pair of legs is selectively received within a respective pocket of the pair of pockets, each leg of the pair of legs including an upward-facing flap, wherein the set of clips is configured to transition from a first open position, in which each upward-facing flap is received within a respective pocket of the pair of pockets, to a second closed position, in which each upward-facing flap is positioned within the remaining portion of the channel with an internal dimension smaller than the internal dimension that extends between the pair of pockets.
16. Coupling system according to claim 15, Petition 870250083290, dated 09 / 16 / 2025, page 85 / 87 5 / 5 characterized in that the saddle includes a groove formed through the first lateral surface and the second lateral surface, the groove configured to selectively receive the upward-facing flap of the leg pair when the clip assembly is placed in the second closed position.
17. Coupling system according to claim 15, characterized in that each leg of the pair of legs of the clip assembly ends in a hook that extends into a gap formed between the pair of legs.
18. Coupling system according to claim 17, characterized in that each hook of the leg pair defines a channel for receiving a portion of a module rail of a solar module.
19. Coupling system according to claim 15, characterized in that the crown defines an arched profile that extends between the pair of legs.
20. Coupling system according to claim 15, characterized in that the pair of legs is open in a direction extending from the crown. Petition 870250083290, dated 09 / 16 / 2025, pp. 86 / 87