Adjustable clamp assembly for solar modules

Abstract

The present disclosure describes a solar power generation system comprising a track, a solar module, and a plurality of adjustable clamps for securing the solar module to the track. The clamp comprises at least a base member, an elastomeric support member, a bracket member, and an alignment member configured to secure the various members of the clamp together. The adjustable clamp is configured to slide within a slot defined by a portion of a surface of the track and comprising a recessed edge, thereby allowing the track system to accommodate solar modules of various sizes.

Description

Technical Field

[0001] The present disclosure relates to a clamp assembly suitable for mounting at least one solar module to a support structure or track of a solar power generation system. More particularly, the present disclosure relates to an adjustable clamp assembly configured to slide along the surface of a support structure or track of a solar power generation system to secure the solar module to a track, frame or rack. The clamp assembly includes at least one base member, an elastomeric support member, a bracket member and an alignment member. Background Art

[0002] Solar energy has long been viewed as an important alternative energy source. To this end, significant effort and investment has been made to develop and improve solar energy collection technology. Of particular interest are residential, industrial, and commercial type applications where relatively large amounts of solar energy can be collected and utilized to supplement or meet electricity needs. One way to implement solar energy collection technology is by assembling multiple arrays of solar modules.

[0003] Solar power generation systems use solar modules including solar panels made of amorphous, crystalline or monocrystalline silicon or other materials to convert sunlight into electricity. Typically, multiple solar modules are interconnected with wiring to one or more appropriate electrical components (e.g., switches, inverters, junction boxes, etc.) and enclosed in a weatherproof barrier or frame.

[0004] Regardless of the exact construction of the PV laminate, most PV applications require the placement of an array of solar modules at a mounting point that is located in a location that receives ample sunlight. This is particularly true for residential, commercial or industrial applications where multiple solar modules are required to generate large amounts of energy.

[0005] In some arrangements, solar modules are placed side by side in an array. Each solar module can be mounted to a support structure, such as a track, by coupling the module to the support structure (e.g., a track) through a coupling member (e.g., a clamp assembly). Coupling modules side by side is challenging because the array assembler typically engages the coupling member while also ensuring that adjacent modules are properly positioned on the support structure. Therefore, there remains a need for improved systems and methods for mounting solar modules to a support structure. Summary of the invention

[0006] The present disclosure provides a solar power generation system, which includes a track, a solar module, and a plurality of clamp assemblies configured to fix the solar module to the track. The clamp assembly is configured to be slidably attached to the track, thereby maintaining the ability to slide along the top surface of the track to accommodate solar modules of different sizes. Each clamp assembly includes a first proximal portion configured to attach and ultimately bolt or fix to the track and a second distal portion configured to receive and fix the end of the solar module within a portion of the clamp assembly. The clamp assembly fixes the solar module to the track via both the first and second portions.

[0007] The present disclosure provides a clamp assembly configured to mount a solar module to a railing system. The clamp assembly described herein includes at least one base member, a bracket member, an elastomeric support member sandwiched between the base member and the bracket member, and an alignment member.

[0008] The base member is configured to slide along the surface of the track of the railing system. The base member is also configured to carry the elastomeric support member and the bracket member when the base member slides. The base member also includes a base aperture defined therethrough. In some embodiments, the base aperture is centered on the base member. In some embodiments, the base member is generally planar. In some embodiments, the base includes a plurality of tangs extending from the bottom surface of the base member. In some embodiments, the base member includes at least one set of tangs separated by a distance equal to or greater than the width of the track and extending generally perpendicularly from the bottom surface of the base member.

[0009] The support member is configured to be positioned on a top surface of the elastomeric support member opposite the base member. The support member provides additional support to the elastomeric support member to secure the solar module within the elastomeric support member. The support member is made of a harder and / or more rigid material than the elastomeric support member. The support member also includes a support aperture.

[0010] In some embodiments, the bracket member further comprises a vertical bracket wall including a first end and a second opposite end, the first end of the vertical bracket wall being attached to a lower flange extending therefrom in a first direction, the lower flange comprising a bracket aperture, and the second opposite end of the vertical bracket wall being attached to an upper flange extending therefrom in a second direction opposite to the first direction.

[0011] In some embodiments, the bracket component further includes at least one locking tab positioned on the upper flange. In some embodiments, the lower flange extends from the first end of the vertical bracket wall by a first length that is greater than a second length that the upper flange extends from the second opposite end of the vertical bracket wall. In some embodiments, the lower flange extends from the first end of the vertical wall at a first angle equal to about 90°, and the upper flange extends from the second opposite end of the vertical bracket wall at a second angle less than about 90°. In some embodiments, the bracket component is an S-shaped bracket component.

[0012] The elastomeric support member is configured to be positioned on a top surface of the base member opposite the track. The elastomeric support member is also configured to receive a bracket member on a proximal portion of the support member and a solar module on a distal portion of the support member. The elastomeric support member also includes a support aperture.

[0013] In some embodiments, the elastomeric support member includes a support base having a first support base portion and a second support base portion. In some embodiments, the top surface of the first base portion is configured to receive the lower flange of the bracket member, and the top surface of the second base portion is configured to receive the end of the solar module.

[0014] In some embodiments, the first support base portion is thinner than the second support base portion. In some embodiments, a combination of the thickness of the first support base portion and the thickness of the lower flange of the support member is equal to the thickness of the second support base portion.

[0015] In some embodiments, the second support base portion of the support base further includes a vertical support member extending generally vertically therefrom and including a generally C-shaped recess on a free end opposite the second support base portion. The C-shaped recess is configured to receive the upper flange and at least one locking tab of the vertical bracket wall. In some embodiments, the generally C-shaped recess includes a first larger recess configured to receive an end of the upper flange and optionally a second smaller recess configured to receive at least one locking tab.

[0016] In some embodiments, the second support base portion, the vertical support member, and the C-shaped recess exhibit substantially the same thickness.

[0017] In some embodiments, the vertical support member includes a plurality of gripping elements extending from an outer surface of the C-shaped recess opposite the top surface of the second support base portion.

[0018] The alignment member has an elongated body defined between a first end and a second end. The first end includes a head, and the elongated body includes a passage extending therethrough. The alignment member also includes an elastic locking member fixed on the outer perimeter of the elongated body between the first and second ends. The elongated body is configured to position a base aperture, a support aperture, and a bracket aperture by fixing a base member, an elastomeric support member, and a bracket member between the head of the alignment member and the elastic locking member to form a clamp assembly.

[0019] In some embodiments, the locking member is spaced apart from the head of the alignment member by a distance equal to or less than the combined thickness of the first support base portion and the thickness of the lower flange of the bracket member to lock the bracket member, the elastomeric support member and the base member between the head and the elastic locking member.

[0020] In some embodiments, the channel of the alignment member is threaded to receive a fastener. In some embodiments, the outer surface of the alignment member is not threaded. In some embodiments, the fastener is positioned in a channel extending through the entire alignment member to secure the clamp assembly to the track.

[0021] The clamp assembly described herein can be combined with at least one solar module and a track configured to support the solar module to form a solar power generation system or a kit for a solar power generation system. The track includes at least one (if not more than one) track groove defined within the track and configured to receive one or more clamp assemblies, as described herein. In an embodiment, the track groove includes a recessed edge configured to receive the head of the alignment member therein.

[0022] Also described are methods of mounting solar modules, and particularly frameless glass solar modules, onto tracks of a solar power generation system using the clamp assemblies described herein. BRIEF DESCRIPTION OF THE DRAWINGS

[0023] Various aspects of the present disclosure are described below with reference to the drawings, which are incorporated into and form part of this specification, in which:

[0024] Figure 1A is an expanded perspective view of a clamp assembly described in at least one embodiment herein;

[0025] Figure 1B yes Figure 1A An expanded side view of a clamp assembly as described in at least one embodiment herein;

[0026] Figure 2A is a perspective view of a clamp assembly and rail described in at least one embodiment herein;

[0027] Figure 2B yes Figure 2A A side view of a clamp assembly and rail as described in at least one embodiment herein;

[0028] Figure 2C yes Figure 2A A front end view of a clamp assembly and rail as described in at least one embodiment herein;

[0029] Figure 2D yes Figure 2A A top view of a clamp assembly and rail as described in at least one embodiment herein;

[0030] Figure 2E is a perspective view of a rail prior to attaching a clamp assembly thereto as described in at least one embodiment herein;

[0031] Figure 3A and 3C is a side view of a clamp assembly and rail described in at least one embodiment herein;

[0032] Figure 3B and 3D They are Figure 3A and 3C and as described in at least one embodiment herein; and

[0033] Figure 4A and 4B is a side view of a clamp assembly, rail, and solar module described in at least one embodiment herein. DETAILED DESCRIPTION

[0034] As described herein, the present disclosure describes an adjustable clamp assembly suitable for mounting at least one solar module to a railing system of a solar power generation system. The solar power generation system may be any type of solar power generation system, such as a rooftop solar power generation system or a solar tracking system, and the like. In a particular embodiment, the solar power generation system includes a glass solar module that may or may not be frameless, and the clamp assembly described herein.

[0035] Solar modules, and in certain embodiments frameless solar modules including glass solar modules, may be attached to mounting rails using the adjustable clamp assemblies described herein. Figure 1A Depicted is an expanded perspective view of an adjustable clamp assembly 100 configured to slide along a surface of a mounting track, the clamp assembly including an alignment member 110 , a base member 120 , an elastomeric support member 130 , and a bracket member 140 .

[0036] The base member 120 is configured to be fixed to the top side of the end of the mounting rail in a manner that allows the base member 120 to slide a predetermined distance along the end of the mounting rail (see Figures 2A to 4B ). The predetermined distance is equal to the length of the slot defined by the end of the mounting rail in which the portion of the clamp assembly is positioned. The base member may be made of any suitable metal or metal alloy material, including (but not intended to be limited to) steel, aluminum, iron, and the like.

[0037] like Figure 1A , the base member 120 is substantially planar and is configured to lie flat along and directly contact the top side of the mounting track. The base member 120 includes a base length (bl) and a base width (bw), wherein the base length (bl) extends along a longitudinal axis A of the base member 120, and the base width (bw) extends perpendicular to the longitudinal axis A. The base length (bl) is greater than the base width (bw) of the base member 120. The base width (bw) is greater than or equal to the width of the mounting track.

[0038] The substrate member 120 includes a top surface 121 opposite a bottom surface 122 with a substrate thickness 123 defined therebetween. A substrate aperture 125 is defined completely through the thickness 123 of the substrate member 120. In some embodiments, the substrate aperture 125 is centered on the substrate member 120. As depicted, the substrate aperture 125 may be hexagonal, however, it is contemplated that the substrate aperture 125 may be any polygonal shape or configuration. Some non-limiting examples of suitable polygonal shapes include triangles, squares, rectangles, pentagons, hexagons, heptagons, octagons, and the like.

[0039] The base member 120 may also include a plurality of base openings 126 and a plurality of tangs 127. The base openings 126 are positioned around the base aperture 125 through the top surface 121 of the base member 120. In some embodiments, the base openings 126 are equidistant from the base aperture 125. The tangs 127 extend away from the bottom surface 122 of the base member 120 in a plane substantially perpendicular to the longitudinal axis A of the base member 120. The tangs 127 are configured to hold the base member 120 positioned on the top side of the track. In some embodiments, at least two tangs 127 are spaced apart from each other by a distance substantially equal to or slightly greater than the width of the track to stabilize the base member 120 and / or the clamp assembly 100 on the surface of the track. In some embodiments, at least two pairs of tangs 127 are spaced apart from each other by a distance substantially equal to or slightly greater than the width of the track.

[0040] As depicted, in some embodiments, at least a portion of each base opening 126 is formed by leaving out a portion of the base member 120. As further depicted, the portion of the base member 120 that is left out to form the base opening 126 can be bent to form the tang 127. In such examples, the base opening 126 and the tang 127 share a common portion of the base member 120 that defines the boundary of the base opening 126 and also attaches the tang 127 to the base member 120.

[0041] The clamp assembly also includes a bracket member 140. The bracket member 140 includes a vertical bracket wall 142 attached to a lower flange 141 on a first end 142a and attached to an upper flange 143 on a second opposite end 142b, the upper flange 143 including at least one locking tab 144 positioned on a top surface 143a of the upper flange 143. The lower flange 141 extends from the first end 142a of the vertical bracket wall 142 at a proximal end, i.e., away from the solar module, and the upper flange 143 extends from the second end 142b of the vertical bracket wall 142 at a distal end, i.e., toward the solar module. The lower flange 141 further includes a bracket aperture 145.

[0042] The lower flange 141 includes a lower bracket length (lbl) that is substantially equal to the vertical bracket length (vbl) of the vertical bracket wall 142, both lbl and vbl being substantially greater than the upper bracket length (ubl) of the upper flange 143. The combination of the lower and upper bracket lengths is equal to the total length of the vertical bracket wall 142. The bracket member 140 may be made of any suitable metal or metal alloy material, including (but not intended to be limited to) steel, aluminum, iron, and the like.

[0043] The lower flange 141 and the vertical support wall 142 form a first angle (a1) ranging from about 75 to 105 degrees. In some embodiments, the first angle (a1) ranges from about 85 to 95 degrees. In some embodiments, the first angle (a1) is about 90 degrees.

[0044] The upper flange 143 and the vertical support wall 142 form a second angle (a2) ranging from about 45 to 90 degrees. In some embodiments, the second angle (a2) ranges from about 55 to 85 degrees. In some embodiments, the second angle (a2) ranges from about 60 to 80 degrees.

[0045] In some embodiments, the bracket member 140 is a generally S-shaped bracket member 140. The bracket member and / or S-shaped bracket member is configured to matingly engage the elastomeric support member 130, as described in more detail below.

[0046] The elastomeric support member 130 is configured to be positioned between the bracket member 140 and the base member 120. The elastomeric support member 130 includes a bottom support surface 130a configured to be positioned on the top surface 121 of the base member 120. The elastomeric support member 130 also includes a top support surface 130b configured to receive the bracket member 140 and the end of the solar module. The proximal portion of the elastomeric support member is sandwiched between the bracket member 140 and the base member 120. The distal portion of the elastomeric support member is positioned between the solar module and the base member 120.

[0047] The elastomeric support member 130 includes a support base 136 including a first support base portion 137 and a second support base portion 138. The first support base portion 137 is configured to receive the lower flange 141 of the bracket member 140. The second support base portion 138 is configured to receive the end of the solar module. Therefore, the second support base portion 138 is positioned closest to the solar module and the first support base portion 137 is positioned farthest from the solar module.

[0048] As depicted, second support base portion 138 has a thickness T1 that is greater than thickness T2 of first support base portion 137. In some embodiments, thickness T1 of second support base portion 138 is substantially equal to a combination of thickness T2 of first support base portion 137 and thickness T3 of lower flange 141 of bracket member 140.

[0049] The first support base portion 137 may also include a first notch 139 positioned on the proximal end 130c of the elastomeric support member 130. As shown, the first notch 137 may be a C-shaped first notch. The first notch 139 is configured to receive the proximal end 141a of the lower flange 141 of the bracket member 140 to further secure the bracket member 140 to the elastomeric support member 130.

[0050] The second support base portion 138 includes a vertical support member 131 extending substantially perpendicularly from a proximal end 138a of the second support base portion 138. The vertical support member 131 is configured to matingly engage a vertical bracket wall 142, an upper flange 143, and a locking tab 144 of the bracket member 140. The vertical support member 131 includes a vertical support wall 132 extending substantially perpendicularly to the second support base portion 138 and a second notch 133, in some embodiments a second C-shaped notch, positioned on an end 132a of the vertical support wall 132.

[0051] The second recess 133 is configured to open at the proximal end to receive the upper flange 143 and the locking tab 144 of the support member 140. The second recess 133 includes a first recess 134a configured to receive and retain the upper flange 143 of the support member 140 and optionally a second recess 134b configured to receive and retain the locking tab 144. In some embodiments, the combination of the vertical support wall 132 and the second recess 133 forms a generally P-shaped vertical support member 131.

[0052] As in Figure 1A and 1B 1, the bottom outer surface 133a of the second recess 133 includes a grip member 101 extending from the second recess 133, and in particular, the bottom outer surface 133a of the second recess 133 toward the second support base portion 138 and into the module slot 103. Any number of grip members 101 may be positioned on the bottom outer surface 133a of the second recess 133. The grip member 101 is configured to increase the friction between the bottom surface 133a of the second recess 133 and the top surface of the solar module.

[0053] The module slot 103 is configured to receive and hold the end of the solar module (see Figures 4A to 4B ). The groove 103 is formed between and / or defined by portions of the second support base portion 138 and the vertical support member 131. In some embodiments, the groove 103 is formed between and / or defined by an outer bottom surface 133a of a second recess 133 that overhangs the proximal end of the second support base portion 138 and is spaced from the proximal end of the second support base portion 138 by the vertical support wall 132. In some embodiments, the top surface of the second support base portion 138 can be textured 107 to further secure and retain the end of the solar module within the module groove 103.

[0054] The elastomeric support member 130 also includes a support aperture 135. The design of the support aperture 135 and the support aperture 145 can be polygonal, respectively. In some embodiments, at least one of the support aperture 135 or the support aperture 145 can be rectangular. In some embodiments, at least one of the support aperture 135 or the support aperture 145 can be hexagonal.

[0055] In some embodiments, support aperture 135 is a polygon that is different from at least one (if not both) of substrate aperture 125 or support aperture 145. For example, Figure 1A, substrate aperture 125 is hexagonal, while support aperture 135 is rectangular and has a larger surface area than substrate aperture 125. In some embodiments, substrate aperture 125 and support aperture 135 are the same polygonal configuration, such as (for example) hexagonal, while support aperture 145 is a different polygonal configuration, such as (for example) rectangular. In still other embodiments, substrate aperture 125, support aperture 135, and support aperture 145 are all the same polygonal shape, such as hexagonal.

[0056] When the base member 120, the elastomeric support member 130, and the bracket member 140 are properly assembled, each of the base aperture 125, the support aperture 135, and the bracket aperture 145 will be vertically aligned along a vertical axis B (substantially perpendicular to the longitudinal axis A) to allow the alignment member 110 to pass therethrough. The alignment member 110 includes an elongated body 111 extending from a head 112 on a first end of the alignment member 110 to a second end 111b of the elongated body 111. The elongated body 111 has a length or height sufficient to pass through each of the base aperture 125, the support aperture 135, and the bracket aperture 145 and extend beyond the bracket aperture 145 of the clamp assembly 100. The elongated body 111 of the alignment member 110 also includes a channel 114 defined therethrough from the first end 111a to the second end 111b. The channel 114 is configured to receive fasteners to secure the base member, the support member, and the bracket member to the rail. A passage 114 extends through the head 112 of the alignment member 110 .

[0057] The alignment member 110 further includes an elastic locking member 113 surrounding the outer perimeter of the elongated body 111. The locking member 113 is spaced apart from the head 112 along the length of the elongated body 111 by a distance substantially equal to or slightly less than the combined thickness 123 of the base member 120, the first support base portion 137, and the lower flange 141. The locking member 113 is configured to fix and hold the base member 120, the support member 130, and the bracket member 140 together against the head 112 of the alignment member 110. By being spaced apart by a distance substantially equal to or slightly less than the common thickness of the base member 120, the first support base portion 137, and the lower flange 141, the elastic locking member 113 and the head 112 of the alignment member 110 are able to squeeze each of the base member 120, the support member 130, and the bracket member 140 therebetween. In some embodiments, the elastic locking member is made of an elastomeric material such as a rubber material, and the head of the alignment member is made of a hard, non-elastic material such as steel or aluminum.

[0058] As in Figure 2DAs best depicted in FIG. 1 , the outer perimeter (p1) of the locking member 113 is greater than the outer perimeter (p2) of the elongated body 111 surrounding the alignment member 110. In some embodiments, the outer perimeter (p1) of the locking member 113 is less than or equal to the outer perimeter of the head 112. Figure 2D As further depicted in other figures provided herein, in some embodiments, the locking member 113 can be generally circular or rounded, such as compared to the polygonal configuration of the elongated body 111 or each of the apertures 125, 135, 145 of the alignment member 110 described herein. It is believed that the elastic nature of the locking member 113, alone or in combination with the generally circular or rounded configuration of the locking member 113, allows the locking member 113 to pass through apertures of various sizes and polygonal shapes while maintaining the ability to secure each of the base member 120, the support member 130, and the bracket member 140 between the head 112 of the alignment member 110.

[0059] In some embodiments, the locking member 113 is an O-ring secured to the outer circumference of the elongated body 111 of the alignment member 110 .

[0060] The alignment member 110 including the head 112 and the elongated body 111 may be made of any suitable material, including but not limited to any combination of plastic or metal materials, alone or in combination. Some suitable non-limiting examples include polycarbonate, acrylonitrile butadiene styrene, steel, aluminum, iron, and the like.

[0061] Both the elastomeric support member and the locking member of the alignment member may be made of any suitable elastomeric material. Representative non-limiting examples of elastomeric materials include natural rubber, polybutadiene rubber, styrene-butadiene copolymer, polychloroprene rubber, ethylene propylene copolymer, ethylene-propylene-diene terpolymer, acrylonitrile-butadiene copolymer, polyisoprene rubber, isobutylene-isoprene copolymer, chlorinated polyethylene rubber, chlorosulfonated polyethylene rubber, silicone rubber, polyurethane rubber, acrylic rubber, polyisobutylene rubber, fluororubber, fluorosilicone rubber and blends thereof. In some embodiments, the elastomeric material is injected with a conductive material to render the elastomeric material conductive, thereby allowing the clamp assembly to be used as a ground between the solar module and the track. In some embodiments, the locking member and the support member are made of the same elastomeric material. In some embodiments, the locking member and the support member are made of different elastomeric materials.

[0062] In some embodiments, at least one of the substrate aperture, support aperture, or bracket aperture has the same geometric configuration of the fastener nut to prevent the fastener nut from rotating freely when positioned in the fixture. In some embodiments, the substrate aperture and bracket aperture are the same geometric configuration as the fastener nut. In some embodiments, the support aperture has a different geometric configuration than at least one (if not all) of the substrate aperture, bracket aperture, or fastener nut.

[0063] Go to Figures 2A to 2E , showing an adjustable clamp 200 positioned or secured to an end 251 of a track 250 configured to secure a solar module (not shown). Clamp 200 (as well as clamps 300 and 400a, 400b described below) includes each of the elements of clamp 100. As depicted, track 250 may include first and second side walls 252, 253 separated from each other by a top wall 254 that creates a channel 255 therebetween. In some embodiments, side walls 252, 253 may be generally L-shaped.

[0064] As depicted, fastener 205 passes through track slot 260 recessed from the bottom side of track 254 into top wall 254, base aperture 225, support aperture 235, and bracket aperture 245 (see FIG. Figure 2E ). The fastener 205 includes a head 206 configured to drive the fastener 205 into the threaded channel of the alignment member 210. The head 206 of the fastener 205 extends from the bottom surface of the top wall 254 and into a portion of the channel 255.

[0065] As in Figure 2E 254, the edge 261 around the track slot 260 in the top wall 254 is recessed and also extends slightly into a portion of the channel 255. The edge 261 around the track slot 260 is configured to receive the head (not shown) of the alignment member 210 therein so that the head 212 of the alignment member 210 can sit flat within the recessed edge 261 and also slide along the recessed edge 261 to allow the clamp assembly to be slidably adjusted along the length of the top wall 254 of the track 250. The length is determined by the length of the track slot 260 and / or the recessed edge 261. By being slidably adjustable, the clamp assembly 200 and the overall track system can accommodate solar modules of different sizes as needed.

[0066] like Figures 2A to 2E As further depicted in FIG. 1 , the width of the clamp assembly 200, and in particular the width of the base member of the clamp assembly 200, is greater than the width of the top rail 254. The tangs 227 of the clamp assembly 200 are separated from each other by a distance generally equal to or slightly greater than the width of the top wall 254 of the rail 250 to help retain the clamp assembly 200 on the top rail 254 and prevent the clamp assembly 200 from being desoldered from the top rail 254 when sliding.

[0067] exist Figures 3A to 3D , a clamp assembly 300 is illustrated wherein each of the parts of the assembly, namely the base member, the support member, the bracket member, and the alignment member, are matingly engaged with each other and positioned on the top wall 354 of the track 350 in a manner suitable for sliding along the top track 354. Figure 3A and 3B , the clamp assembly 300 is shown in the furthest position on the track 350, i.e., closest to the solar module, with the head 312 of the alignment member 310 positioned on the track edge 361 within the track groove 360. From below the track 350, the channel 314 of the alignment member 310 can be seen within the track groove 360, the channel 314 waiting to receive a fastener from the bottom side of the top wall 354 of the track 350 to secure the clamp assembly 300 to the track 350.

[0068] exist Figures 3C to 3D , the clamp assembly 300 is shown in the closest position on the track 350, i.e., farthest from the end of the solar module, with the head 312 of the alignment member 310 positioned within the track slot 360. The channel 314 of the alignment member 310 is ready to receive a fastener from the bottom side of the top wall 354 of the track 350 to secure the clamp assembly 300 to the track 350. In some embodiments, as shown in FIG. Figures 3C to 3D As shown in , the proximal end 336 of the base member 320 can extend beyond the end 351 of the track 350.

[0069] Fasteners (not shown) may be positioned within channel 314 and not fully tightened to allow clamp assembly 300 to be loosely secured to track 350, i.e., attached to the track but remaining able to slide and / or adjust along the length of the track. Once the ends of the solar modules are received within the module slots of the elastomeric support members, the fasteners may be tightened to secure clamp assembly 300 relative to track 350 and the solar module.

[0070] exist Figures 4A to 4B, a solar rack system including a mounting structure 480, a track 450, a support arm 470, a solar module 490, and a plurality of clamp assemblies 400a, 400b as described herein is shown. The mounting structure 480 is configured to be mounted to a torque tube, vertical support, or other beam suitable for supporting the rack system. The track 450 is attached to and extends from the mounting structure 480. The support arm 470 also extends from the mounting structure 480 to a distal portion of the underside of the track 450 to provide additional mechanical support or strength to the track 450 to maintain the weight of the solar module 490 in a fixed planar configuration. In some embodiments, the track 450 and the support arm 470 can pivot about the mounting structure 480. In some embodiments, the support arm 470 can further lock the track 450 into a horizontal or vertical position via a side slot 490 having a side rail 432, where the support arm 470 is attached to the track 450.

[0071] Although only one track and support arm are depicted, the solar rack systems and kits for solar rack systems described herein may include multiple tracks, support arms, clamp assemblies, and solar modules as desired. Additionally, although depicted from a side view in which the clamp assemblies described herein are only positioned on two opposing sides of a solar module, it is contemplated that the clamp assemblies may be positioned on more than two opposing sides of a solar module to secure the module to the track. For example, in some embodiments, the tracks described herein may be interconnected to form a grid that surrounds the outer perimeter of a solar module as a whole, and the clamp assemblies may be used to secure the module to the track on all sides of the solar module.

[0072] In some embodiments, the solar modules may be secured to a track system. Figures 4A to 4B, in some embodiments, a method of securing a solar module 490 to a solar rack system 500 includes: providing a first rail 450 attached to a base support structure 480, the first rail 450 including at least one first rail slot defined therethrough and including a recessed edge around a perimeter of the first rail slot; positioning first and second clamp assemblies 400a, 400b within the first rail slot, wherein the first and second clamp assemblies 400a, 400b each include a base member 420a, 420b, support members 430a, 430b, bracket members 440a, 440b, and alignment members 410a, 410b described herein, and fasteners 405a, 405b that loosely or temporarily secure the clamp assemblies 400a, 400b to the rail 450 (and in particular, to a top wall 454 of the rail 450); inserting a first end 490a of the solar module 490 into the first clamp assembly 400a 400a, 400b; and the first and second clamp assemblies 400a, 400b are fixed to the track 450.

[0073] In some embodiments, solar module 490 may initially be tilted relative to track 450, such as Figure 4A 400a, to assist in inserting the first end 490a of the solar module 490 into the first clamp assembly 400a. In such embodiments, the tilting solar module 490 can be advanced into the first clamp assembly 400a while simultaneously or sequentially inserting the second opposite end 490b of the solar module 490 (e.g., by Figure 4A The second fixture assembly 400b is lowered to a position substantially parallel to the second fixture assembly 400b, as shown by the arrow. Figure 4B Instructions.

[0074] In some embodiments, once substantially parallel, any combination of the first and second clamp assemblies 400a, 400b may be slid inwardly toward the solar module 490 (eg, by Figure 4BIn some embodiments, the solar module 490 is vertically spaced from the top wall 454 of the track 450 by the thickness (T5) of the base member 420 of the elastomeric support members 430a, 430b and the support bases 438a, 438b.

[0075] In some embodiments, the method utilizes a first and a second clamp assembly, the first and the second clamp assemblies comprising: a base member, which is configured to slide along the surface of a first track, the base member comprising a base aperture; an elastomeric support member, which is configured to be positioned on the top surface of the base member opposite the track, the elastomeric support member comprising a support aperture; a bracket member, which is configured to be positioned on the top surface of the elastomeric support member opposite the base member, the bracket member comprising a bracket aperture; and an alignment member, which has an elongated body defined between a first end and a second end, the first end comprising a head and the elongated body comprising a channel extending therethrough, the alignment member comprising an elastic locking member fixed on the outer periphery of the elongated body between the first and second ends, the elongated body being positioned by fixing the base member, the elastomeric support member and the bracket member to the base aperture, the support aperture and the bracket aperture between the head of the alignment member and the elastic locking member.

[0076] In some embodiments, the first clamp assembly is secured within the first track slot and the second clamp assembly is secured within the second track slot, wherein the first and second track slots are positioned on ends of the first track.

[0077] In some embodiments, the first clamp assembly can be secured to the track in a fixed position before the first end of the solar module is inserted into the first clamp assembly.

[0078] In some embodiments, the first clamp assembly can be secured to the track in a fixed position after the first end of the solar module is inserted into the first clamp assembly.

[0079] In some embodiments, the second clamp assembly may be secured to the track in the fixed position only after the second end of the solar module is inserted into the second clamp assembly and the first clamp assembly is in the fixed position.

[0080] Although the clamp assembly, track, solar module and solar power generation system have been described in conjunction with several different embodiments, it should be understood that the present application is not intended to be limited to only those embodiments. Rather, many modifications and variations will be apparent to those skilled in the art without departing from the scope and spirit of the present application.

Claims

1. An adjustable clamp assembly for mounting at least one solar module to a railing system, the clamp assembly comprising, a base member configured to slide along a surface of the track, the base member comprising a base aperture, an elastomeric support member configured to be positioned on a top surface of the base member opposite the track, the elastomeric support member including a support aperture, a bracket member configured to be positioned on a top surface of the elastomeric support member opposite the base member, the bracket member including a bracket aperture, and an alignment member having an elongated body defined between a first end and a second end, the first end including a head and the elongated body including a passage extending therethrough, the alignment member including a resilient locking member secured to an outer perimeter of the elongated body between the first end and the second end, the elongated body being positioned through the base aperture, the support aperture and the bracket aperture, thereby securing the base member, the elastomeric support member and the bracket member between the head of the alignment member and the resilient locking member to form the clamp assembly, Wherein the base member further includes at least one set of tangs separated by a distance equal to or greater than the width of the track and extending generally perpendicularly from a bottom surface of the base member.

2. The adjustable clamp assembly of claim 1, wherein the base member is generally planar.

3. An adjustable clamp assembly according to claim 1, wherein the bracket member further includes a vertical bracket wall including a first end and a second opposite end, the first end of the vertical bracket wall is attached to a lower flange extending therefrom in a first direction, the lower flange includes the bracket aperture, and the second opposite end of the vertical bracket wall is attached to an upper flange extending therefrom in a second direction opposite to the first direction.

4. The adjustable clamp assembly of claim 3, wherein the bracket member further comprises at least one locking tab positioned on the upper flange.

5. The adjustable clamp assembly of claim 3, wherein the lower flange extends a first length from the first end of the vertical bracket wall that is greater than a second length that the upper flange extends from the second opposite end of the vertical bracket wall.

6. The adjustable clamp assembly of claim 3, wherein the lower flange extends from the first end of the vertical bracket wall at a first angle equal to approximately 90°, and the upper flange extends from the second opposite end of the vertical bracket wall at a second angle less than approximately 90°.

7. The adjustable clamp assembly of claim 3, wherein the elastomeric support member comprises a support base including a first support base portion and a second support base portion, the top surface of the first support base portion being configured to receive the lower flange of the bracket member, and the top surface of the second support base portion being configured to receive the end of the solar module.

8. The adjustable clamp assembly of claim 7, wherein the first support base portion is thinner than the second support base portion.

9. The adjustable clamp assembly of claim 7, wherein a combination of a thickness of the first support base portion and a thickness of the lower flange of the bracket member is equal to a thickness of the second support base portion.

10. An adjustable clamp assembly according to claim 9, wherein the locking member is spaced apart from the head of the alignment member by a distance equal to or less than the combination of the thickness of the first supporting base portion and the thickness of the lower flange of the bracket member to lock the bracket member, the elastomeric support member and the base member between the head and the elastic locking member.

11. An adjustable clamp assembly according to claim 7, wherein the second support base portion further includes a vertical support member extending generally vertically therefrom and including a generally C-shaped recess on a free end opposite to the second support base portion, the C-shaped recess being configured to receive at least one locking tab of the upper flange and the vertical bracket wall.

12. The adjustable clamp assembly of claim 11, wherein the generally C-shaped recess includes a first larger recess configured to receive an end of the upper flange and a second smaller recess configured to receive the at least one locking tab.

13. The adjustable clamp assembly of claim 11, wherein the second support base portion, the vertical support member, and the C-shaped recess exhibit substantially the same thickness.

14. The adjustable clamp assembly of claim 11, further comprising a plurality of gripping elements extending from an outer surface of the C-shaped recess opposite a top surface of the second support base portion.

15. The adjustable clamp assembly of claim 11, further comprising a fastener positioned within a passage extending through the alignment member.

16. The adjustable clamp assembly of claim 15, wherein the channel of the alignment member is threaded to receive a fastener and an outer surface of the alignment member is unthreaded.

17. A solar power generation system, comprising: Rails for supporting solar modules, a track groove defined in an end of the track, and An adjustable clamp assembly configured to secure the solar module to the track via the track slot, the adjustable clamp assembly comprising a base member configured to slide along a surface of a track, the base member including a base aperture, an elastomeric support member configured to be positioned on a top surface of the base member opposite the track, the elastomeric support member including a support aperture, a bracket member configured to be positioned on a top surface of the elastomeric support member opposite the base member, the bracket member including a bracket aperture, and An alignment member having an elongated body defined between a first end and a second end, the first end including a head and the elongated body including a channel extending therethrough, the alignment member including an elastic locking member fixed on the outer periphery of the elongated body between the first end and the second end, the elongated body being positioned through the track slot, the base aperture, the support aperture and the bracket aperture, thereby fixing the base member, the elastomeric support member and the bracket member between the head of the alignment member and the elastic locking member to form the clamp assembly, wherein the base member further includes at least one set of tangs separated by a distance equal to or greater than the width of the track and extending generally perpendicularly from the bottom surface of the base member.

18. A kit for a solar power generation system, comprising: a plurality of rails configured to support solar modules, each rail including a rail slot defined in an end of the rail, and A plurality of adjustable clamp assemblies configured to fix the solar module to the track via the track slot, each slidable clamp assembly comprising a base member configured to slide along a surface of a track, the base member including a base aperture, an elastomeric support member configured to be positioned on a top surface of the base member opposite the track, the elastomeric support member including a support aperture, a bracket member configured to be positioned on a top surface of the elastomeric support member opposite the base member, the bracket member including a bracket aperture, and an alignment member having an elongated body defined between a first end and a second end, the first end including a head and the elongated body including a passage extending therethrough, the alignment member including a resilient locking member secured to an outer perimeter of the elongated body between the first end and the second end, the elongated body being positioned through the base aperture, the support aperture and the bracket aperture, thereby securing the base member, the elastomeric support member and the bracket member between the head of the alignment member and the resilient locking member to form the clamp assembly, Wherein the base member further includes at least one set of tangs separated by a distance equal to or greater than the width of the track and extending generally perpendicularly from a bottom surface of the base member.

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