Fast locking module track for solar tracker

Abstract

A coupling system for use with a solar tracker includes a support rail (12) defining opposing top and bottom surfaces, the top surface configured to support a portion of a solar module (140); and a fastening assembly (80) operably coupled to a portion of the support rail (12), the fastening system including a retaining bolt (82) having an elongate head (84) including opposing top and bottom surfaces (84b, 84c) extending between opposing first and second end portions (84d, 84e), the retaining bolt (82) having a first end portion (84d) and a second end portion (84e) extending between the first end portion (84d) and the second end portion (84e), and the first end portion (84d) and the second end portion (84e) extending between the first end portion (84d) and the second end portion (84e). Wherein the bottom surface (84c) of the elongate head (84) is offset from the top surface of the support rail (12) to define a gap configured to selectively receive a portion of a solar module (140) therein.

Description

[0001] Related Applications Cross Reference

[0002] This application claims the benefit of U.S. Provisional Application No. 63 / 350,954, filed on June 10, 2022, the contents of which are hereby incorporated by reference in their entirety. Technical Field

[0003] The present disclosure relates to solar power generation systems, and more particularly to clamps and clamping systems for securing solar modules to support structures. Background Art

[0004] Solar cells and solar panels are most efficient in sunny conditions when oriented at a specific angle toward the sun. Many solar panel systems are designed in conjunction with solar trackers that track the sun's path across the sky from east to west in order to maximize the system's power generation capabilities. The relatively low energy generated by a single solar cell requires the use of thousands of solar cells arranged in an array to generate enough energy to be used, for example, as part of an energy grid. As a result, fairly large solar trackers have been developed that span hundreds of feet in length and contain hundreds to thousands of individual solar modules mechanically coupled to a support structure.

[0005] Coupling numerous solar modules to a support structure requires a large number of clamps or other mechanisms, each of which requires a large number of fasteners, thereby increasing the cost of manufacturing each mechanism. As can be appreciated, assembling each of these mechanisms and securely tightening each fastener requires a large amount of time, resulting in increased costs and long assembly times. The present disclosure seeks to address the shortcomings of existing tracker systems. Summary of the invention

[0006] According to one aspect of the present disclosure, a coupling system for use with a solar tracker includes: a support rail defining opposing top and bottom surfaces, the top surface being configured to support a portion of a solar module; and a fastening assembly operably coupled to a portion of the support rail, the fastening system including a retaining bolt having an elongated head, the elongated head including opposing top and bottom surfaces extending between opposing first and second end portions, wherein the bottom surface of the elongated head is offset from the top surface of the support rail to define a gap, the gap being configured to selectively receive a portion of a solar module therein.

[0007] In various aspects, the coupling system can include a spring arm operably coupled to the bottom surface of the support rail and including an upturned flange configured to extend beyond the top surface of the support rail.

[0008] In particular aspects, a portion of the solar module can include a retaining groove defined therethrough, the retaining groove configured to receive a portion of the elongated head of the retaining bolt therein.

[0009] In other aspects, the upturned flange of the spring arm can be configured to be received within the retaining groove when the solar module is in the second position such that the elongated head cooperates with the upturned flange to prevent movement of the solar module relative to the support rail.

[0010] In particular aspects, the coupling system can include a biasing element interposed between the bottom surface of the elongated head and the top surface of the support rail to bias the elongated head away from the top surface of the support rail.

[0011] In various aspects, the biasing element can be configured to be compressed to adjust the distance between the bottom surface of the elongated head and the top surface of the support track.

[0012] In other aspects, the coupling system may include a nut threadably engaged to a portion of the retaining bolt, the nut configured to compress the biasing element when rotated in a first direction and enable extension of the biasing element when rotated in a second, opposite direction.

[0013] In various aspects, the retaining bolt may include a boss disposed on the bottom surface of the elongated head, the boss extending from the bottom surface and terminating at a lower surface that abuts a portion of the top surface of the support rail to define the gap.

[0014] In certain aspects, the elongated head can define a racetrack-shaped profile.

[0015] According to another aspect of the present disclosure, a fastening assembly for use with a solar module includes: a retaining bolt, the retaining bolt including: a slender head including opposing top and bottom surfaces extending between opposing first and second end portions; and a boss disposed on a portion of the bottom surface of the elongated head and disposed adjacent to one of the first and second end portions, wherein the bottom surface of the elongated head is offset from a lower surface of the boss to define a gap configured to selectively receive a portion of the solar module therein.

[0016] In various aspects, the fastening assembly can include a spring arm configured to selectively engage a portion of a solar module.

[0017] In other aspects, the fastening assembly can include a biasing element disposed adjacent the bottom surface of the elongated head and configured to be compressed to alter a size of the gap.

[0018] In particular aspects, the boss may extend from the bottom surface of the elongated head and terminate at a lower surface, the distance between the bottom surface of the elongated head and the lower surface of the boss defining the size of the gap.

[0019] In other aspects, the elongated head can define a racetrack-shaped profile.

[0020] According to another aspect of the present disclosure, a method of coupling a solar module to a support rail includes: aligning a retaining groove defined on a portion of the solar module with an elongated head of a retaining bolt, wherein a lower surface of the retaining bolt is offset relative to an upper surface of the support rail to define a gap therebetween; advancing the solar module toward the upper surface of the support rail such that a portion of the elongated head of the retaining bolt is received within the retaining groove; and advancing the solar module in a first longitudinal direction such that a portion of the solar module is received within the gap, thereby selectively retaining the solar module to the support rail.

[0021] In various aspects, advancing the solar module toward the upper surface of the support rail can include causing a portion of the solar module to abut a portion of an upturned flange of a spring arm operably coupled to a portion of the support rail and causing the upturned flange to be compressed.

[0022] In particular aspects, advancing the solar module in the first longitudinal direction causes the upturned flange of the spring arm to decompress and be received within a portion of the retaining recess.

[0023] In other aspects, the method may include rotating a nut threadably engaged to a portion of the retaining bolt in a first direction to alter a size of the gap.

[0024] In particular aspects, rotating the nut in the first direction may include rotating the nut in the first direction to compress a biasing element interposed between the lower surface of the retaining bolt and the upper surface of the support rail, thereby changing a size of the gap. BRIEF DESCRIPTION OF THE DRAWINGS

[0025] Various aspects and features of the present disclosure are described below with reference to the drawings, in which:

[0026] Figure 1 is a perspective view of a clamp assembly provided in accordance with the present disclosure, the clamp assembly being illustrated as being coupled to a torque tube;

[0027] Figure 2 yes Figure 1 A perspective view of a fixture assembly;

[0028] Figure 3 yes Figure 1 An exploded view of the fixture assembly;

[0029] Figure 4 yes Figure 1 A perspective view of a support track of a clamp assembly;

[0030] Figure 5 yes Figure 4 Elevation drawing of the support track;

[0031] Figure 6 yes Figure 4 Magnified view of the area of ​​detail indicated in ;

[0032] Figure 7 yes Figure 1 an elevation view of a strip assembly of a clamp assembly;

[0033] Figure 8 yes Figure 7 A perspective view of a strap bolt of a strap assembly;

[0034] Fig. 9 yes Figure 7 A perspective view of a trunnion of a strip assembly;

[0035] Fig.10 yes Figure 1 A front perspective view of a retaining bolt of a fastening assembly of a clamp assembly;

[0036] Fig.11 yes Fig.10A rear perspective view of a retaining bolt;

[0037] Fig.12 yes Figure 1 A perspective view of a spring arm of a fastening assembly of a clamp assembly;

[0038] Fig.13 yes Fig.12 Elevation view of the spring arm;

[0039] Fig.14 yes Figure 1 An elevation view of a portion of a fixture assembly of FIG. 1 , illustrating the coupling to Figure 4 Support track Fig.10 The retaining bolts and Fig.12 Spring arm;

[0040] Fig.15 yes Figure 1 A perspective view of a portion of a fixture assembly illustrating coupling to Figure 4 Support track Fig.10 The retaining bolts and Fig.12 Spring arm;

[0041] Fig.16 is for Figure 1 A perspective view of a solar module used with a clamp assembly;

[0042] Fig.16A yes Fig.16 Magnified view of the area of ​​detail indicated in ;

[0043] Fig.17 It is a graphic description Fig.16 Elevation view of a solar module, the solar module is placed Figure 1 above the fixture assembly and Fig.10 Keep the bolts aligned;

[0044] Fig.18 It is a graphic description Fig.10 An elevation view of a retaining bolt, the retaining bolt being received in a Fig.16 within a retaining groove in a solar module;

[0045] Fig.19 It is a graphic description Fig.12 An elevation view of a portion of a spring arm received in Fig.16 The solar module is held in a recess and Fig.10 The retaining bolts and Fig.16 A portion of the solar module engages to Fig.16 The solar modules are kept to Figure 4 On the support track;

[0046] Fig. 20 is a front perspective view of another embodiment of a retaining bolt provided according to the present disclosure;

[0047] Fig.21 yes Fig. 20 A rear perspective view of a retaining bolt;

[0048] Fig. 22 is for Fig. 20 A perspective view of a biasing element used with a retaining bolt;

[0049] Fig.23 yes Fig. 22 A side elevation view of a biasing element disposed in Fig. 20 The threaded shank and boss of the retaining bolt;

[0050] Fig.24 yes Figure 4 A perspective view of a support rail for receiving Fig. 20 square bore for retaining bolt;

[0051] Fig.25 is coupled to Figure 4 Support track Fig.23 A perspective view of a retaining bolt and biasing element assembly;

[0052] Fig.26 yes Figure 4 A perspective view of an alternative embodiment of a support track;

[0053] Fig. 27 is a perspective view of an alternative embodiment of a clamp assembly provided in accordance with the present disclosure;

[0054] Fig.28 yes Fig. 27 A perspective view of a support track of a clamp assembly;

[0055] Fig.29 yes Fig.28 Magnified view of the area of ​​detail indicated in ;

[0056] Fig.30 yes Fig. 27 an exploded view of a fastening assembly of a clamp assembly;

[0057] Fig.31 yes Fig.30 A top perspective view of a retaining bolt of a fastening assembly;

[0058] Fig.32 yes Fig.31 A bottom perspective view of a retaining bolt;

[0059] Fig.33 yes Fig.30 A perspective view of a biasing element of a fastening assembly;

[0060] Fig.34 yes Fig.30 A perspective view of a retaining washer of a fastening assembly;

[0061] Fig.35 yes Fig.30 A perspective view of another embodiment of a retaining washer of a fastening assembly;

[0062] Fig.36 yes Fig. 27 A perspective view of a clamp assembly of , illustrating the clamp assembly placed in an initial open position;

[0063] Fig.37 yes Fig. 27 A plan view of a clamp assembly of , illustrating the clamp assembly placed in an initial open position;

[0064] Fig.38 yes Fig. 27 , illustrating the clamp assembly placed in a second clamped position;

[0065] Fig.39 is coupled to Fig. 27 a perspective view of a solar module of a fixture assembly; and

[0066] Fig.40 is coupled to Fig. 27 Elevation view of a solar module with a clamp assembly. DETAILED DESCRIPTION

[0067] The present disclosure relates to a coupling system for use with a solar tracker. The coupling system described herein reduces the number of fasteners required to couple a solar module to a torque tube and reduces the amount of labor required to install and / or adjust the solar module on the torque tube. The coupling system includes a support rail, a strap assembly, and a fastening assembly. The support rail is configured to be selectively secured to the torque tube of the solar tracker via the strap assembly. In this manner, the strap assembly is operably coupled to the support rail and includes a strap that is configured to be clamped or otherwise selectively secured to the torque tube by tightening bolts and a trunnion assembly. The support rail includes a spring arm operably coupled to a lower surface and includes an upturned flange that protrudes beyond an upper surface of the support rail. The spring arm is formed of an elastic material so that the upturned flange can be selectively depressed to be flush with or below the upper surface of the support rail and return to its original position once the force is removed from the upturned flange.

[0068] The support rail also includes a plurality of retaining bolts having a generally "L" shaped profile. In this manner, each retaining bolt includes an elongated head having a boss defined on a lower surface thereof. The boss is generally disposed concentrically with the arcuate end portion of the elongated head such that the boss is offset from a central portion of the elongated head. The boss includes an outer surface that is generally flush with an outer surface of the elongated head and includes a lower surface configured to abut an upper surface of the support rail. As can be appreciated, by abutting the upper surface of the support rail, the length of the boss defines a gap between the lower surface of the elongated head and the upper surface of the support rail, the gap being configured to selectively receive a portion of a solar module therein. In an embodiment, the boss may include an outer dimension that is less than an outer dimension of the elongated head such that the boss may be received within a retaining slot formed within a portion of the solar module. In this manner, a biasing element may be disposed above the boss such that the biasing element is interposed between the lower surface of the elongated head and the upper surface of the rail to bias the elongated head in a direction away from the upper surface of the rail. The boss includes a threaded shank disposed thereon, the threaded shank being configured to threadably engage a nut, which, when rotated in a first direction, causes the lower surface of the elongated head to be pulled toward the upper surface of the support rail and compress the biasing element, and when rotated in a second direction, the nut enables the biasing element to bias the elongated head away from the upper surface of the support rail to adjust the size of the gap to accommodate different thicknesses of solar modules.

[0069] In operation, the solar module is positioned over the elongated heads of the plurality of retaining bolts such that the elongated heads are generally aligned with the corresponding retaining slots of the solar module. The solar module is advanced toward the upper surface of the support rail such that the elongated heads are received within the retaining slots and the bottom surface of the solar module abuts a portion of the upturned flanges of the spring arms. Continued advancement of the solar module toward the upper surface of the support rail causes the upturned flanges to be depressed until the bottom surface of the solar module abuts the upper surface of the support rail. At this point, the solar module is pulled or otherwise slid in a longitudinal direction such that a portion of the solar module is received within a gap formed between the lower surface of the elongated heads and the upper surface of the support rail. Continued sliding of the solar module in the longitudinal direction causes the upturned flanges of the spring arms to align with and be received within a portion of the retaining slots to prevent longitudinal movement of the solar module relative to the support rail. As can be appreciated, by capturing a portion of the solar module within the gap, in cooperation with the upturned flanges of the spring arms, the solar module is prevented from moving relative to the support rail, thereby coupling the solar module to the torque tube of the solar tracker.

[0070] In aspects where the biasing element is interposed between the lower surface of the elongated head and the upper surface of the support rail, once a portion of the solar module is received within the gap, the nut is rotated in a first direction to clamp or otherwise secure the retaining bolt to the solar module to prevent movement of the solar module relative to the support rail. As can be appreciated, the use of the spring arm may be optional when utilizing a biasing element.

[0071] In an embodiment, the retaining bolt and spring arm can be received in an elongated slot defined in a portion of the support rail, the elongated slot being defined transverse to the longitudinal axis. In this manner, the position of the retaining bolt and spring arm can be adjusted to accommodate misalignment and / or different solar module designs. The assembly process is substantially similar to the process described above, i.e., once the portion of the solar module is received in the gap, the nut is tightened to secure the position of the retaining bolt relative to the support rail and couple the solar module to the support rail.

[0072] In another embodiment, the retaining bolt includes an elongated boss defined on a lower surface of the elongated head to engage a portion of a biasing element interposed between the lower surface of the elongated head and the upper surface of the support track. The biasing element includes a generally circular center portion and an upper arm and a lower arm. The upper arm defines a first portion extending generally tangentially from an outer circumference of the center portion and a second portion defined generally orthogonal to the first portion, the second portion being configured to engage the elongated boss of the retaining bolt. The lower arm extends generally tangentially from an outer circumference of the center portion and defines an internal angle generally less than 90 degrees relative to the first portion of the upper arm. The lower arm includes a downwardly turned tab defined on an end portion thereof, the downwardly turned tab being configured to be received in an aperture defined through a portion of the support track, thereby rotatably supporting the biasing element on the support track. The support track defines a keyhole having a circular portion and a notch defined through an outer circumference thereof. The keyhole is configured to rotatably receive a threaded shank of the retaining bolt such that the biasing element biases the elongated head of the retaining bolt in a first opening direction.

[0073] The retaining washer includes a generally circular center portion having four upturned flanges disposed on an outer circumference thereof spaced substantially 90 degrees apart from one another. Three of the upturned flanges are disposed at a diagonal angle relative to the center portion and extend outwardly from the center of the center portion. The fourth upturned flange is disposed generally orthogonal to the center portion and includes a length greater than the length of the remaining three upturned flanges. The retaining washer is interposed between a bottom surface of the support rail and a nut such that when the nut is rotated in a first direction, the nut pushes the support washer toward the bottom surface of the support rail such that the fourth upturned flange is received through the notch of the keyhole. Continued rotation of the nut in the first direction causes the fourth upturned flange to extend beyond the upper surface of the support rail and prevents the elongated head of the retaining bolt from rotating to its original position when the elongated head has been rotated.

[0074] In operation, each of the retaining bolts is placed in an initial portion thereof where the elongated head extends in a direction parallel to a longitudinal axis defined through the support rail. The solar module is placed on the upper surface of the support rail such that an upturned flange defined on the upper surface of the support rail is received within a corresponding bore defined within a portion of the solar module to substantially position the solar module relative to the support rail. With the solar module resting on the upper surface of the support rail, the nut is rotated in a first direction, which causes the retaining bolt to act on the biasing element and rotate the elongated head toward the solar module to capture a portion of the solar module within a gap formed between a lower surface of the elongated head and an upper surface of the support rail until a portion of the elongated head abuts a portion of the upturned flange to prevent further rotation of the retaining bolt. Continued rotation of the nut causes the retaining washer to deform or otherwise flatten against the bottom surface of the support rail and causes the fourth upturned flange of the retaining washer to extend beyond the upper surface of the support rail. The position of the fourth upwardly turned flange relative to the elongated head prevents the biasing element from returning the elongated head to its initial position and, in the event that the nut is loosened, prevents the elongated head from rotating to its initial position. Further rotation of the nut causes the lower surface of the elongated head to abut or otherwise clamp against the solar module to prevent the solar module from moving relative to the support rail. These and other aspects of the present disclosure will be described in detail below with reference to the drawings.

[0075] Now refer to the diagram, Figures 1 to 19 A clamp assembly, generally indicated by reference numeral 10, is illustrated for use with a solar module. The clamp assembly 10 includes a support rail 12, a strap assembly 40, and a fastening assembly 80.

[0076] refer to Figures 4 to 6, the support rail 12 includes an elongated body 14 extending between opposite first and second end portions 14a, 14b, respectively, thereby defining a longitudinal axis AA. It is contemplated that the elongated body 14 may include any suitable length (e.g., a dimension extending along the longitudinal axis AA between the first and second end portions 14a, 14b), depending on the design requirements of the clamp assembly 10. The elongated body 14 includes opposite side surfaces 14c and 14d extending between each of the first and second end portions 14a, 14b, and an upper surface 16 extending between the first and second end portions 14a, 14b and each of the opposite side surfaces 14c, 14d. The upper surface 16 defines a first planar portion 16a adjacent to the first end portion 14a and extending toward the second end portion 14b. The first planar portion 16a transitions to a first inclined portion 16b in a direction toward the second end portion 14b. The first inclined portion 16b is angled relative to the first planar portion 16a such that the first inclined portion 16b extends in a downward direction (e.g., opposite the direction that the upper surface 16a faces). The first inclined portion 16b transitions to a central planar portion 16c extending in a direction toward the second end portion 14b, the central planar portion being generally parallel to the first planar portion 16a but offset in a downward direction relative to the first planar portion, but it is contemplated that the central planar portion 16c may define any suitable angle relative to the first planar portion 16a and / or the first inclined portion 16b depending on the design requirements of the clamp assembly 10.

[0077] The central planar portion 16c transitions to a second inclined portion 16d that extends in a direction toward the second end portion 14b along the longitudinal axis AA. The second inclined portion 16d extends in an upward direction (e.g., away from the central planar portion 16c in the same direction as the upper surface 16a faces) and defines an angle relative to the central planar portion 16c that is generally the same as the angle formed between the first inclined portion 16b and the central planar portion 16c, but it is contemplated that the second inclined portion 16d may define any suitable angle relative to the central planar portion 16c depending on the design needs of the clamp assembly 10. The second inclined portion 16d transitions to a second planar portion 16e that is generally parallel and coplanar with the first planar portion 16a, but it is contemplated that the second planar portion 16e may define any suitable angle relative to the first planar portion 16a and be disposed at any distance relative to the first planar portion 16a (e.g., above or below the first planar portion 16a). The second planar portion 16e extends toward the second end portion 14b and terminates at the second end portion. The elongated body 14 includes a pair of downwardly turned flanges 18a and 18b disposed adjacent each of the first end portion 14a and the second end portion 14b, respectively. The pair of downwardly turned flanges 18a, 18b extend in a direction away from the first planar portion 16a and the second planar portion 16e (eg, toward the central planar portion 16c).

[0078] The elongated body 14 defines a lower surface 20 disposed in juxtaposed relation with the upper surface 16 and extending between the first and second end portions 14a, 14b and each of the opposing side surfaces 14c, 14d, respectively. Figure 5 ). The lower surface 20 defines a shape that is generally consistent with the shape of the upper surface 16, except that the lower surface 20 includes a pair of protrusions 22a and 22b disposed on the lower surface in a spaced relationship from each other so as to define a gap 22c therebetween. The pair of protrusions 22a, 22b extend in a downward direction (e.g., in the same direction as the direction facing the lower surface 20) and cooperate with the gap 22c to form a generally inverted saddle or bean-shaped configuration that is configured to selectively receive a portion of the torque tube 130 therein ( Figure 1 and 3). In this manner, the gap 22c includes an inner surface 22d extending between the pair of protrusions 22a, 22b, the inner surface being configured to abut or otherwise contact a portion of the torque tube 130 received within the gap 22c, as will be described in further detail below. As can be appreciated, the gap 22c is configured to receive the torque tube 130 therein, the torque tube having any suitable profile, such as circular, hexagonal, D-shaped, oval, and others. The upper surface 16 includes a cavity 24 defined therein that generally conforms to the profile of the lower surface 20 and the pair of protrusions 22a, 22b. It is contemplated that the support rail 12 may be formed of any suitable material, such as steel, aluminum, polymers, composites, and may be formed using any suitable process, such as machining, additive manufacturing, stamping, hydroforming, and others.

[0079] The first planar portion 16a of the elongated body 14 includes a first pair of bores 26 ( Figure 4 ), the first pair of bores being defined through the first planar portion and extending through the lower surface 20 adjacent to the first end portion 14a and each of the opposing side surfaces 14c, 14d (e.g., in a spaced relationship transverse to the longitudinal axis AA). The first pair of bores 26 are configured to selectively receive a first pair of retaining bolts 82 of a fastening assembly 80, as will be described in further detail below. The second planar portion 16e of the elongated body 14 includes a second pair of bores 28, the second pair of bores being defined through the upper surface 16 and the lower surface 20 adjacent to the second end portion 14b and each of the opposing side surfaces 14c, 14d (e.g., in a spaced relationship transverse to the longitudinal axis AA). The second pair of bores 28 are configured to selectively receive a second pair of retaining bolts 82, as will be described in further detail below. The second planar surface 16e of the elongated body 14 includes a pair of slots 30 defined through the second planar surface and extending through the lower surface 20. The pair of slots 30 are disposed adjacent to the second pair of bores 28 at a position such that the second pair of bores 28 is interposed between the pair of slots 30 and the second end portion 14b. Each of the pair of slots 30 extends in a direction generally transverse to the longitudinal axis AA (e.g., in a direction extending between the opposing side surfaces 14c, 14d). Each of the pair of slots 30 is configured to selectively receive a portion of a corresponding spring arm 90 of a fastening assembly 80, as will be described in further detail below. Although described in detail above, those skilled in the art will recognize that any suitable support rail capable of being used with the strap assembly 40 and the fastening assembly 80 described below may be utilized.

[0080] refer to Figures 7 to 9, the strap assembly 40 includes a strap 42, a strap bolt 60, and a trunnion 70. The strap 42 defines a generally D-shaped profile having first and second legs 44, 46, respectively, joined to a backspan 48 to form a channel 50 therebetween that is configured to selectively receive a portion of a torque tube 130 therein ( Figure 1 ). The backspan 48 defines a generally planar profile extending between opposing first and second end portions 48a, 48b, respectively. Although generally illustrated as having a planar profile, it is contemplated that the backspan 48 may include any suitable profile, such as arcuate, hexagonal, pentagonal, decagonal, and others, and may be the same or different than the profile of the torque tube 130.

[0081] The first leg 44 and the second leg 46 are substantially similar and therefore, for the sake of brevity, only one of the first leg 44 and the second leg 46 will be described in detail herein. The first leg 44 defines a generally lazy "L" shaped profile extending between opposing first and second end portions 44a, 44b, respectively. The first end portion 44a of the first leg 44 is coupled to a first end portion 48a of the backspan. The second end portion 44b of the first leg 44 includes an eyelet or annular ring 44c that is configured to rotatably receive a portion of a strap bolt 60 therein to rotatably couple the strap bolt 60 to the first leg 44. As can be appreciated, the eyelet 46c of the second leg 46 is configured to rotatably receive a portion of a trunnion 70 to rotatably couple the trunnion 70 to the second leg 46. The first leg 44 and the second leg 46 are disposed in juxtaposed relation to one another such that the apertures 44c, 46c of each of the first leg 44 and the second leg 46 are disposed adjacent one another. The first leg 44 and the second leg 46 cooperate to define a gap 52 therebetween that is configured to permit a portion of the torque tube 130 to pass therethrough and into the passage 50, as will be described in further detail below.

[0082] The strap bolt 60 defines a generally "T" shaped profile having a transverse portion 62 defining a pair of legs 62a and 62b disposed at a first end portion 60a of the strap bolt 60 and having a longitudinal threaded portion 64 adjacent the second end portion 60b. The pair of legs 62a, 62b are configured to be rotatably received within the eyelet 44c of the first leg 44 of the strap 42 and the threaded portion 64 is configured to be slidably received within a portion of the trunnion 70 and threadedly engage a nut or other suitable fastening device, as will be described in further detail below. Although generally described as having a bend adjacent the transverse portion 62, it is contemplated that the strap bolt 60 may be straight or otherwise linear along its length, depending on the design requirements of the strap assembly 40. In one non-limiting embodiment, the strap bolt is a curved T-bolt.

[0083] refer to Fig. 9 , the trunnion 70 defines a generally "T" shaped profile having a longitudinal portion 72 extending between opposing first and second end portions 72a, 72b, respectively, and a transverse portion 74 disposed on the second end portion 72b of the longitudinal portion 72 and extending between respective first and second end portions 74a, 74b, respectively. The transverse portion 74 defines a generally circular profile having outer dimensions configured to be rotatably received within the eyelet 46c of the second leg 46. While generally described as having a circular profile, it is contemplated that the transverse portion 74 may include any suitable profile, such as square, oval, racetrack, hexagonal, and others. The longitudinal portion 72 defines a generally circular profile and includes a bore 76 defined therein and extending through the first and second end portions 72a, 72b. The bore 76 is configured to slidably receive a portion of the strap bolt 60 therethrough such that a portion of the longitudinal threaded portion 64 adjacent the second end portion 60b of the strap bolt extends beyond the first end portion 72a of the longitudinal portion 72 of the trunnion 70. As can be appreciated, the longitudinal threaded portion 64 of the strap bolt 60 is permitted to translate within the bore 76 of the trunnion 70 to enable the strap bolt 60 to draw the eyelet 44c of the first leg 44 and the eyelet 46c of the second leg 46 toward each other, thereby clamping or otherwise squeezing the torque tube 130 received within the passage 50 and between each of the first leg 44 and the second leg 46. In this manner, the nut 78 or other suitable fastening device is threadedly coupled to the longitudinal threaded portion 64 of the strap bolt 60 so that when the nut 78 is rotated in a first direction, the nut 78 abuts the first end portion 72a of the ear shaft 70 and causes the eyelets 44c, 46c of the first leg 44 and the second leg 46 to be pulled toward each other, and when the nut 78 is rotated in a second, opposite direction, the nut 78 is caused to be pulled away from the first end portion 72a to permit the eyelets 44c, 46c of the first leg 44 and the second leg 46 to be dragged or pulled away from each other and release the torque tube 130 disposed within the channel 50.

[0084] Return to Figure 1 and 2, the elongated body 14 of the support rail 12 includes one or more slots or bores (not shown) defined therein for receiving a portion of the strap 42 of the strap assembly 40 adjacent the gap 22c and the pair of projections 22a, 22b. In this manner, when the torque tube 130 is received within the channel 50 of the clamp assembly, the torque tube is likewise received within the gap 22c and is retained between the pair of projections 22a, 22b by the pair of legs 44, 46 of the strap assembly 40. As can be understood, when the torque tube 130 is received in the channel 50 of the strip assembly 40 and the gap 22c of the support rail 12, when the nut 78 of the strip assembly 40 is rotated in a first direction, the nut 78 causes the first leg 44 and the second leg 46 to be pulled toward each other and compress or otherwise pull the torque tube 130 against the inner surface 22d of the gap 22c and thereby against the support rail 12 to fix the support rail 12 to the torque tube 130, thereby preventing the torque tube 130 from rotating and translating relative to the support rail 12 and vice versa.

[0085] refer to Figures 10 to 15, the fastening assembly 80 includes a plurality of retaining bolts 82 and a pair of spring arms 90. Each of the plurality of retaining bolts 82 is substantially similar and therefore only one of the plurality of retaining bolts 82 will be described in detail herein for the sake of brevity. The retaining bolt 82 defines a generally "L" shaped profile having an elongated head 84 disposed on a threaded shank 88. The elongated head 84 defines a generally racetrack shaped profile including an outer surface 84a extending between opposing top and bottom surfaces 84b, 84c, respectively. The elongated head 84 defines a generally racetrack shaped profile having a pair of parallel portions extending between opposing arcuate or semicircular portions disposed adjacent opposing first and second end portions 84d, 84e, respectively. Although generally described as having a racetrack shaped profile, it is contemplated that the elongated head may define any suitable profile, such as square, oval, hexagonal, and others. The bottom surface 84c includes a boss 86 disposed on and extending from the bottom surface and terminating at a lower surface 86a. The boss 86 defines a generally elliptical or eye-shaped profile and is disposed on the bottom surface 84c of the elongated head 84 so that the boss 86 is generally concentric with the circular profile of the first end portion 84d. Although generally described as an eye shape, it is conceivable that the boss 86 may include any suitable profile, such as a circle, square, racetrack, ellipse, rectangle, and others. In this way, the boss 86 includes an outer surface 86b extending between the bottom surface 84c and the lower surface 86a of the elongated head 84, which is generally flush with or otherwise coincides with the outer surface 84a of the elongated head 84. As can be appreciated, the boss 86 is offset from the central portion of the elongated head 84 by being formed adjacent to the first end portion 84d of the elongated head 84. The outer dimensions of the outer surface 86b of the boss 86 are greater than the diameter or inner dimensions of the first and second pairs of bores 26, 28 formed in the support rail 12, such that the lower surface 86a of the boss 88 abuts or otherwise contacts a portion of the upper surface 16 of the support rail 12 to block or otherwise prevent the boss 86 from passing through the first and second pairs of bores 26, 28. As can be appreciated, the length of the boss 86 can vary depending on the thickness of the solar module frame to ensure that the solar module frame is properly retained to the support rail 12, as will be described in further detail below. Although generally illustrated as defining planar surfaces, it is contemplated that one or both of the bottom surface 84c of the elongated head 84 and / or the lower surface 86a of the boss 86 can include a plurality of protrusions, serrations or other suitable features defined or disposed thereon to facilitate efficient grounding of the solar module when the solar module is coupled to the elongated bolt, as will be described in further detail below.

[0086] The threaded shank 88 is disposed on and extends longitudinally from the lower surface 86a of the boss 86. The threaded shank 88 includes a generally circular profile and is generally concentric with the boss 86. The threaded shank 88 includes a threaded outer surface 88a that is configured to threadably engage a fastening device such as a nut, as will be described in further detail below. The threaded shank 88 includes an outer dimension that is smaller than the inner dimension of the first pair of bores 26 and the second pair of bores 28, so as to permit the threaded shank to be received through the first pair of bores and the second pair of bores (e.g., into and out of the pair of bores 26, 28). It is contemplated that the retaining bolt 82 may be formed of any suitable material such as a metallic material (e.g., steel, stainless steel, aluminum, and others), a polymer, a ceramic, a composite, and others, depending on the design requirements of the clamp assembly 10. In an embodiment, the retaining bolt 82 may be formed of more than one material (e.g., the elongated head 84 may be formed of a different material than the threaded shank 88, etc.).

[0087] refer to Fig.12 and 13, each of the pair of spring arms 90 is substantially similar and therefore only one of the pair of spring arms 90 will be described in detail herein for the sake of brevity. The spring arm 90 includes an elongated body 92 extending between opposing first and second end portions 92a, 92b, respectively, and between opposing first and second side surfaces 92c, 92d, respectively. The elongated body 92 includes opposing top and bottom surfaces 92e, 94f extending between the first and second end portions 91a, 92b, and between the first and second side surfaces 92c, 92d, respectively. The elongated body 92 defines a generally lazy "L" shaped profile with a rectangular or square shaped tab 94 disposed adjacent the first end portion 92a. The tab 94 transitions to a center portion 96 in a direction toward the second end portion 92b, the center portion having a width that is less than the width of the tab 94 (e.g., the dimension between the first side surface 92c and the second side surface 92d of the tab 94 is greater than the dimension between the first side surface 92c and the second side surface 92d of the rectangular portion 96). The center portion 96 defines an angle relative to the tab 94 in a direction away from the top surface 92e of the tab 94. The center portion 96 transitions to an end portion 98, which forms an angle relative to the center portion 96 in a direction away from the top surface 92e of the center portion 96. The end portion 98 includes an upwardly turned flange 98a extending away from the top surface 92e disposed adjacent the second end portion 92b. Although generally illustrated as forming a generally orthogonal angle relative to the end portion 98, it is contemplated that the upwardly turned flange 98a may form any suitable angle relative to the end portion 98. The upturned flange 98a is configured to be received within a portion of a corresponding slot in the pair of slots 30 and includes a length such that a portion of the upturned flange 98a extends beyond the upper surface 16 of the support rail to selectively engage a corresponding feature formed in the solar module 140, as will be described in further detail below. It is contemplated that the spring arm 90 may be formed of any suitable resilient material that is capable of elastically deforming and generally returning to its original shape.

[0088] refer to Fig.14 The top surface 92e of the tab 94 of the spring arm 90 is coupled to a portion of the lower surface 20 of the support rail 12 using any suitable means (e.g., fasteners, welding, adhesives, etc.). In one non-limiting embodiment, the top surface 92e of the tab 94 of the spring arm 90 is coupled to a portion of the lower surface 20 of the support rail 12 by clinching (e.g., The tab 94 is coupled to the support rail 12 by a staking connection (-staking connection). The spring arm 90 is positioned on the lower surface 20 so that the upturned flange 98a is received through the corresponding slot of the pair of slots 30 and extends beyond the upper surface 16 of the support rail 12. In this way, the top surface 92e of the end portion 98 abuts or otherwise contacts the lower surface 20 of the support rail 12. As can be appreciated, the biasing force of the spring arm 90 biases the top surface 92e of the end portion 98 against the lower surface 20 of the support rail 12 so that when a force is applied to the upturned flange 98a from above the upper surface 16 of the support rail 12, the upturned flange 98a is urged into the slot 30 and causes the spring arm 90 to bend or otherwise deform. When the force is no longer applied to the upturned flange 98a, the spring arm 90 is permitted to return to its original shape and bias the upturned flange 98a through the slot 30.

[0089] refer to Fig.16 and 16A , the solar module 140 includes a frame or support flange 142. The support flange 142 defines a generally L-shaped (angle beam or angle iron) configuration extending between opposing first and second end portions 142a, 142b, respectively. The support flange 142 includes a lower flange 144 that is generally bisected by a vertical flange or wall 146. The lower flange 144 includes opposing first and second side surfaces 144a, 144b, respectively, and opposing top and bottom surfaces 144c, 144d extending between the first and second end portions 142a, 142b, and each of the first and second side surfaces 144a, 144b, respectively. The support flange 142 includes a vertical flange or wall 146 disposed on the top surface 144c adjacent to the second side surface 144b. The lower flange 144 includes a thickness that permits the lower flange 144 to be slidably received between the upper surface 16 of the support rail 12 and the bottom surface 84 c of the elongated head 84 of each of the plurality of retaining bolts 82 .

[0090] The lower flange 144 includes a first retaining groove 146a and a second retaining groove 146b defined through the top surface 144c and the bottom surface 144d, respectively, adjacent each corresponding first end portion 142a and second end portion 142b. As can be appreciated, each of the first retaining groove 146a and the second retaining groove 146b is generally aligned with the first pair of bores 26 and the second pair of bores 28 of the support rail 12 so that adjacent solar modules 140 can be selectively coupled to the support rail 12, as will be described in further detail below. In this way, the support rail 12 is configured to support two adjacent solar modules 140.

[0091] refer to Figure 1 and 16In operation, the nut 78 of the strap assembly 40 is positioned in a loosened state so as to permit the torque tube 130 to be received within the channel 50 formed between the first leg 44 and the second leg 46 of the strap 42 and within the gap 22c defined between the pair of protrusions 22a, 22b of the support rail 12 ( Figure 1 With the torque tube 130 received within the channel 50 and the strap 42 positioned in the desired position on the torque tube, the nut 78 is rotated in a first direction to cause the eyelets 44 c, 46 c to be drawn toward each other and cause the torque tube 130 to be clamped or otherwise secured to the support rail 12, thereby preventing the torque tube 130 from rotating relative to the support rail 12 (e.g., the support rail 12 moves synchronously with the torque tube 130).

[0092] With the torque tube 130 secured to the support rail 12 via the strap assembly 40, the solar module 140 is positioned in a first position above the support rail 12 where the elongated head 84 of each of the plurality of retaining bolts 82 is aligned with a corresponding one of the first and second retaining grooves 146a, 146b of the solar module 140 ( Fig.17 With the elongated heads 84 of the plurality of retaining bolts 82 aligned with the first retaining groove 146a and the second retaining groove 146b of the solar module 140, the solar module 140 is pushed or otherwise moved toward the upper surface 16 of the support rail 12 so that each of the elongated heads 84 of the plurality of retaining bolts 82 is received within a corresponding retaining groove in the first retaining groove 146a and the second retaining groove 146b ( Fig.18 ). In this position, the upwardly turned flanges 98a of the pair of spring arms 90 are offset from the second retaining grooves 146b, so that continued movement of the solar module 140 toward the upper surface 16 of the support rail 12 causes the bottom surface 144d of the lower flange 144 to abut a portion of each of the upwardly turned flanges 98a. Further movement of the solar module 140 toward the upper surface 16 causes the upwardly turned flanges 98a to be pushed or otherwise advanced into the pair of slots 30 of the support rail 12, so that the upper portion of the upwardly turned flanges 98a is substantially coplanar with the upper surface 16 and permits the bottom surface 144d of the lower flange 144 to abut or otherwise contact the upper surface 16 of the support rail 12.

[0093] With the bottom surface 144d of the lower flange 144 of the solar module 140 abutting against the upper surface 16 of the support rail 12, the elongated heads 84 of the plurality of retaining bolts 82 protrude through the first retaining groove 146a and the second retaining groove 146b by a certain amount, thereby permitting the lower flange 144 to be received in the gap formed between the bottom surface 84c of the elongated heads 84 of the plurality of retaining bolts 82 and the upper surface 16 of the support rail 12. At this time, the solar module 140 is pulled or otherwise slid across the upper surface 16 of the support rail 12 toward the first end portion 14a of the support rail 12, so that the corresponding portion of the lower flange 144 is received in the gap formed between the bottom surface 84c of the elongated head 84 of each of the plurality of retaining bolts 82 and the upper surface 16 of the support rail 12 ( Fig.19 ). Continued movement of the solar module 140 toward the first end portion 14a of the support rail 12 causes the upwardly turned flanges 98a of the pair of spring arms 90 to align with corresponding portions of the second retaining groove 146b, which are adjacent to the first end portion 84d of the elongated head 84 of the retaining bolt 82 that is received within the second retaining groove 146b. The alignment of the upwardly turned flanges 98a of the pair of spring arms 90 with the second retaining groove 146b permits the upwardly turned flanges 98a to be biased into the second retaining groove 146b to retain or otherwise prevent movement of the solar module 140 along the longitudinal axis AA in a direction toward the second end portion 14b of the support rail 12. As can be appreciated, capturing the lower flange 144 of the solar module 140 between the bottom surface 84c of the elongated head 84 of each of the plurality of retaining bolts 82 and the upper surface 16 of the support rail 12 prevents movement of the solar module 140 in a direction toward the first end portion 14a of the support rail and lateral and vertical movement of the solar module 140 relative to the support rail 12.

[0094] As can be appreciated, removing the solar module 140 from the support rail 12 follows the process described above in substantially the reverse order, except that the upwardly turned flange 98a of the pair of spring arms 90 is initially pressed down below the bottom surface 144d of the lower flange 144 to disengage the upwardly turned flange 98a from the second retaining groove 146b of the lower flange 144. With the upwardly turned flange 98a of the pair of spring arms 98a disengaged from the second retaining groove 146b, the solar module 140 is permitted to move or otherwise advance toward the second end portion 14b of the support rail 12 to remove the lower flange 144 from between the bottom surface 84c of the elongated head 84 of each of the plurality of retaining bolts 82 and the upper surface 16 of the support rail 12 and allow the elongated head 84 of each of the plurality of retaining bolts 82 to be removed from the first retaining groove 146a and the second retaining groove 146b of the solar module 140, and thus permit the solar module 140 to be removed from the support rail 12.

[0095] Go to Figures 20 to 25 , another embodiment of a retaining bolt is illustrated and generally indicated by the reference numeral 100. Retaining bolt 100 is substantially similar to retaining bolt 88 and therefore, for the sake of brevity, only the differences therebetween will be described in detail herein.

[0096] The boss 108 of the retaining bolt 100 includes outer dimensions that are substantially the same as the outer dimensions of the threaded shank 110, such that the boss 108 can be received within bores in the first pair of bores 26 and the second pair of bores 28 of the support rail 12. In this manner, a portion of the bottom surface 104c of the elongated head 104 is exposed around the circumference of the boss 108. The biasing element 112 is configured to be disposed above the boss 108 and adjacent to a portion of the bottom surface 104c of the elongated head 104 and a portion of the upper surface 16 of the support rail 12 (e.g., the threaded shank 110 and the boss 108 are configured to be received within an interior portion of the biasing element 112). In this manner, the biasing element 112 is interposed between the bottom surface 104c of the elongated head 104 and the upper surface 16 of the support rail 12. In an embodiment, the first pair of bores 26 and the second pair of bores 28 of the support rail 12 may include a square configuration ( Fig.24 ) rather than a circular configuration to help prevent the biasing element from being received through the first pair of bores 26 and the second pair of bores 28. Although generally described as both the first pair of bores 26 and the second pair of bores 28 having a square configuration, it is contemplated that only one of the first pair of bores 26 and the second pair of bores 28 may include a square configuration, or that either or all of the first pair of bores 26 and the second pair of bores 28 may include any suitable configuration, such as an oval, a rectangle, a racetrack, a hexagon, and others.

[0097] The biasing element 112 biases the elongated head 104 away from the upper surface 16 to form a gap between the bottom surface 104c and the upper surface 16. The size of this gap between the bottom surface 104c and the upper surface 16 can be adjusted to accommodate different wall thicknesses of the support rail 12 by rotating a nut 114 threadedly engaged with the threaded shank 110 of the retaining bolt 100 in a first direction to reduce the gap (e.g., causing the biasing element 112 to be compressed) or rotating the nut 114 in a second, opposite direction to increase the gap (e.g., causing the biasing element 112 to push the elongated head 104 away from the upper surface 16).

[0098] It is contemplated that the biasing element 112 may be any suitable biasing element, such as a coil spring, a belleville washer, a wave spring, a finger spring, a polymer spring, a rubber o-ring, a flower-shaped washer, and others. In one non-limiting embodiment, the biasing element 112 is a spring washer or a split washer. As can be appreciated, by allowing adjustment of the gap formed between the bottom surface 104c of the elongated head 104 and the upper surface 16 of the support rail 12, the gap may be pre-adjusted during manufacture of the clamp assembly 10. During field assembly, only a half turn or a full turn of the nut 114 is required to secure the retaining bolt 100 to the support rail 12, and thus secure the solar module 140 to the support rail 12, thereby further reducing the amount of time required to secure the solar module 140 to the support rail and reducing the amount of different retaining bolts 100 manufactured for support rails 12 having different thicknesses. As can be appreciated, the assembly process of the clamp assembly 10 utilizing the retaining bolt 100 is substantially similar to the assembly process of the clamp assembly 10 utilizing the retaining bolt 82, except that once the lower flange 144 of the solar module 140 is received within the gap formed between the lower surface 104c of the retaining bolt 100 and the upper surface 16 of the support rail 12, the nut 114 is tightened to secure the lower flange 144 between the lower surface 104c of the retaining bolt 100 and the upper surface 16 of the support rail 12. It is contemplated that when utilizing the retaining bolt 100 and the biasing element 112, the spring arm 90 may be omitted because clamping the retaining bolt 100 to the flange 144 of the solar module 140 effectively couples the clamp assembly 10 to the solar module 140 and prevents relative movement between the clamp assembly and the solar module.

[0099] Go to Fig.26In an embodiment, it is contemplated that the first pair of bores 26 and the second pair of bores 28 may be elongated along a direction extending between each of the opposing side surfaces 14c, 14d. In this manner, the first pair of bores 26 and the second pair of bores 28 may include an elliptical or racetrack-shaped profile, but it is contemplated that the first pair of bores 26 and the second pair of bores 28 may include any suitable profile, such as a rectangle, etc. Although generally described as both the first pair of bores 26 and the second pair of bores 28 being elongated, it is contemplated that only one of the first pair of bores 26 and the second pair of bores 28 or individual bores of the first pair of bores 26 and the second pair of bores 28 may be elongated, while the remaining bores have a different profile (e.g., circular, square, hexagonal, etc.).

[0100] It is contemplated that the pair of slots 30 may also be elongated in a direction extending between each of the opposing side surfaces 14c, 14d of the support rail 12 in a manner similar to the elongated first and second pairs of bores 26, 28. As can be appreciated, the support rail 12 may include a corresponding pair of spring arm slots 30a defined through the upper and lower surfaces 16, 20 on a portion of the second inclined portion 16d of the support rail to receive a portion of a rivet or other suitable fastener to couple the spring arm 90 to the support rail 12. In this manner, the elongated pair of slots 30 and the pair of spring arm slots 30a enable the lateral position of the spring arm 90 to be adjusted. As can be appreciated, the elongated first and second pairs of bores 26, 28 cooperate with the elongated pair of slots 30 and the pair of spring arm slots 30a to accommodate solar modules 140 having first and second retaining grooves 146a, 146b arranged at different spacings. In this manner, assembly of the clamp assembly 10 to the solar module 140 is substantially similar to the assembly described above utilizing the retaining bolt 100 and biasing element 112, except that the retaining bolt 100 and a pair of spring arms 90 (if utilized) are initially horizontally aligned with the first retaining groove 146a and the second retaining groove 146b prior to proceeding with the assembly procedure described in detail above.

[0101] Go to Figures 27 to 38 , another embodiment of a clamp assembly provided in accordance with the present disclosure is illustrated and generally indicated by reference numeral 200. The clamp assembly 200 includes a support rail 212, a clamp assembly 40, and a fastening assembly 280.

[0102] refer to Figures 27 to 29, the support rail 212 is substantially similar to the support rail 12 described above and therefore, for the sake of brevity, only the differences therebetween will be described in detail herein. The second planar portion 216e includes a pair of upwardly turned flanges 232 disposed on and extending perpendicularly from the upper surface 216 (e.g., in the same direction as the direction the upper surface 216 faces). Each of the pair of upwardly turned flanges 232 is disposed in a mirrored or side-by-side relationship with each other about a longitudinal axis AA defined by the opposing first end portion 214a and the second end portion 214b of the support rail 212. Each of the pair of upwardly turned flanges 232 extends generally along the longitudinal axis AA, such that the pair of upwardly turned flanges 232 define a generally square configuration, but it is contemplated that the pair of upwardly turned flanges 232 may include any suitable configuration, such as rectangular, oval, circular, and others. Although generally illustrated as being formed by die cutting, it is contemplated that the pair of upturned flanges 232 may be formed using any suitable method, such as welding, fasteners, adhesives, hydroforming, additive manufacturing, stamping, machining, and others. Each of the pair of upturned flanges 232 is configured to be received within a corresponding bore defined within a portion of the solar module 140, as will be described in further detail below.

[0103] continue Figures 27 to 29, the second planar portion 216e of the support rail 212 includes a pair of keyholes 226 defined through the upper surface 216 and the lower surface 220. The pair of keyholes 226 define a generally circular profile having a notch 226a cut through its outer circumference (e.g., a keyhole shape) that is configured to receive a portion of a retaining washer therethrough, as will be described in further detail below. The pair of keyholes 226 are disposed on either side of the longitudinal axis AA (e.g., the first keyhole is closest to the first side surface 214c and the second keyhole is closest to the second side surface 214d) and are in a flipped configuration. In this manner, the notch 226a of the keyhole 226 disposed closest to the first side surface 214c faces the second end portion 214b and the notch 226a of the keyhole 226 disposed closest to the second side surface 214d faces the first end portion 214a. The keyhole 226 disposed closest to the first side surface 214c is offset toward the second end portion 214b relative to the pair of upturned flanges 232, and the keyhole disposed closest to the second side surface 214d is offset toward the first end portion 214a relative to the pair of upturned flanges 232, and each of the pair of keyholes 226 is disposed closer toward each of the opposing first and second side surfaces 214c, 214d than the pair of upturned flanges 232. Although generally described as being disposed in the positions described above, it is contemplated that each of the pair of keyholes 226 and the pair of upturned flanges 232 may be disposed at positions relative to each other, depending on the design requirements of the clamp assembly 200.

[0104] The second planar portion 216e of the support plate includes a pair of apertures 234 defined through the upper surface 216 and the lower surface 220 for receiving a portion of the biasing element of the fastening assembly 280. Each of the pair of apertures 234 is disposed adjacent to a corresponding keyhole of the pair of keyholes 226 on a side adjacent to each of the opposing first side surface 214c and the second side surface 214d, respectively. Although generally illustrated as including a circular profile, it is contemplated that the pair of apertures 234 may include any suitable profile, such as square, hexagonal, oval, rectangular, and others, and may include the same or different profiles compared to one another. The first planar portion 216a of the support rail 212 is similar to the second planar portion 216e and includes the pair of upwardly turned flanges 232 disposed adjacent to the first end portion 214a, the pair of keyholes 230, and the pair of apertures 234.

[0105] refer to Figures 30 to 35, the fastening assembly 280 includes a retaining bolt 282, a biasing element 290, a retaining washer 300, and a nut 320. The clamp assembly 200 includes a plurality of fastening assemblies 280, each of which is substantially similar to one another and thus only one fastening assembly 280 will be described in detail herein for the sake of brevity.

[0106] The retaining bolt 282 defines a generally "L" shaped profile having an elongated head 284 disposed on a threaded shank 286. The elongated head 284 defines a generally racetrack shaped profile including an outer surface 284a extending between opposing top and bottom surfaces 284b, 284c, respectively. The elongated head 284 defines a generally racetrack shaped profile having a pair of parallel portions 284d and 284e extending between opposing arcuate or semicircular portions disposed adjacent opposing first and second end portions 284f, 284g, respectively. The threaded shank 286 is disposed on the bottom surface 284c, substantially concentric with the arcuate profile of the elongated head 284 adjacent the first end portion 284f, and includes an outer dimension that is less than the outer dimension of the outer surface 284a, such that a portion of the bottom surface 284c of the elongated head 284 is exposed around the circumference of the threaded shank 286.

[0107] The bottom surface 284c of the elongated head 284 includes an elongated boss 288 disposed thereon that is configured to engage with a corresponding portion of the biasing element 290, as will be described in further detail below. The bottom surface 284c of the elongated head 284 includes a plurality of serrations or protrusions 284h defined therein or disposed thereon that are configured to grasp a portion of the solar module 140 or otherwise enhance the ability of the bottom surface 284c to grasp a portion of the solar module, but it is contemplated that the bottom surface 284c of the elongated head 284 may include any suitable contour, such as planar, convex, concave, among others.

[0108] refer to Fig.33, the biasing element 290 defines a generally modified coil spring configuration having a circular center portion 292 and a pair of upper and lower legs 294, 296 extending therefrom. The upper leg 294 includes a first linear portion 294a extending generally tangentially from the center portion 292. The first linear portion 294a transitions to a second linear portion 294b disposed at a generally orthogonal angle relative to the first linear portion 294a, although it is contemplated that the first and second linear portions 294a, 294b may form any suitable angle relative to each other and the center portion 292. The second linear portion 294b extends in a direction generally across the center portion, but is offset relative thereto, and is configured to engage an elongated boss 288 of the retaining bolt 282, as will be described in further detail below.

[0109] The lower leg 296 extends generally tangentially from the central portion 292, defining an internal angle relative to the upper leg 294 that is generally less than 90 degrees, but it is contemplated that the lower leg 296 may define any suitable angle relative to the upper leg 294, depending on the design requirements of the clamp assembly 200. The lower leg 296 transitions into a downwardly turned tab 296a that extends in a direction away from the upper leg 294. The downwardly turned tab 296a defines a generally orthogonal angle relative to the lower leg 296 and is configured to be received within an aperture in a pair of apertures 234 of the support rail 212 to rotatably retain the biasing element 290 to the support rail 212. The biasing element 290 is formed of any suitable resilient material such that the biasing element can be resiliently deformed and substantially return to its original shape.

[0110] refer to Fig.34, the retaining gasket 300 defines a generally circular center portion 302 including four upturned flanges 304a, 304b, 304c, and 304d extending from the generally circular center portion and disposed 90 degrees apart from one another around the circumference of the center portion 302. The upturned flanges 304a, 304b, and 304c are disposed at a diagonal angle relative to the center portion (e.g., between parallel to the center portion 302 and orthogonal to the center portion) such that when a force is applied to each of the upturned flanges 304a, 304b, and 304c, each of the upturned flanges 304a, 304b, and 304c is caused to deform or otherwise flatten and provide a biasing force in reaction thereto. The upturned flange 304d is disposed at a generally orthogonal angle relative to the center portion 302 and includes a length that is generally greater than the length of each of the upturned flanges 304a, 304b, and 304c. The upturned flange 304d is configured to be received within a portion of the recess 226a of the support rail 212, thereby maintaining the orientation of the retaining washer 300 relative to the support rail 212 and, therefore, relative to the retaining bolt 282, as will be described in further detail below. The center portion 302 includes a bore 302a defined therethrough that is configured to receive a portion of the threaded shank 286 of the retaining bolt 282 therethrough.

[0111] refer to Fig.35 , another embodiment of a retaining washer is illustrated and generally indicated by reference numeral 310. The retaining washer 310 includes a biasing element 312 that is substantially similar to the biasing element 112 described above and therefore will not be described in further detail below. The biasing element 312 includes an upturned flange 314 disposed on a portion thereof, the upturned flange being disposed at a generally orthogonal angle relative to the biasing element 312 (e.g., generally parallel to a longitudinal axis defined through a central portion of the biasing element 312). The upturned flange 314 is configured to be received within a portion of the recess 226a of the support rail 212, thereby maintaining the orientation of the retaining washer 310 relative to the support rail 212 and, therefore, relative to the retaining bolt 282, as will be described in further detail below. The biasing element 312 includes a bore 312a defined therethrough that is configured to receive a portion of the threaded shank 286 of the retaining bolt 282 therethrough.

[0112] As can be appreciated, the biasing element 312 provides a biasing force that resists compression thereof. It is contemplated that the biasing element 312 may be any suitable biasing element, such as a coil spring, a Belleville washer, a wave spring, a finger spring, a polymer spring, a rubber o-ring, and others. In one non-limiting embodiment, the biasing element 312 is a spring washer or a split washer and may be formed of any suitable elastic material that permits elastic deformation of the biasing element and permits the biasing element 312 to substantially return to its original shape.

[0113] Return to Fig.30 , upon assembly, the downwardly turned tab 296a of the lower leg 296 of the biasing element 290 is advanced within the aperture 234 of the support rail 212 such that the biasing element 290 is rotatably supported by the support rail 212. The threaded shank 286 of the retaining bolt 282 is advanced within the keyhole 226 adjacent the aperture 234, with the downwardly turned tab 296a of the biasing element 290 received therein. The retaining bolt 282 is further advanced within the keyhole 226 and is oriented such that the elongated head 284 extends in the same direction as the notch 226a extends. Further advancement of the retaining bolt 282 within the keyhole 226 causes the second linear portion 294b of the upper leg 294 of the biasing element to engage the elongated boss 288 of the retaining bolt 282 such that rotation of the retaining bolt 282 within the keyhole results in corresponding deformation of the biasing element 290, as will be described in further detail below.

[0114] With the retaining bolt 282 received within the keyhole 226, the retaining washer 300 is advanced over the threaded shank 286 of the retaining bolt 282 such that the threaded shank 286 is received within the bore 302a of the retaining washer 300. The retaining washer 300 is further advanced over the threaded shank 282 toward the lower surface 220 of the support rail 212 such that the upturned flange 304d is received within the recess 226a of the keyhole 226 and a portion of each of the upturned flanges 304a, 304b, and 304c abuts or otherwise contacts a portion of the lower surface 220 of the support rail 212. At this point, the nut 320 threadably engages the threaded shank 286 of the retaining bolt 282 and is rotated in the first direction, causing the nut 320 to abut the retaining washer 300 or otherwise cause it to be advanced toward the lower surface 220 of the support rail 212. As can be appreciated, the biasing element 290 causes the elongated head 284 of the retaining bolt 282 to be biased in a direction generally parallel to the longitudinal axis AA. Fig.36). As the nut 320 is further rotated in the first direction, the upwardly turned flanges 304a, 304b, and 304c are compressed against the lower surface 220 of the support rail 212 and are generally deformed into a flat shape (e.g., generally parallel to the lower surface 220 of the support rail 212). The compression of the upwardly turned flanges 304a, 304b, and 304c causes the upwardly turned flange 304d to protrude an increased distance beyond the upper surface 216 of the support rail 212, and as the elongated head 284 of the retaining bolt 282 is rotated substantially 90 degrees (e.g., forming a substantially orthogonal angle relative to the longitudinal axis AA), the upwardly turned flange 304d is abutted against the elongated head 284 of the retaining bolt 282 or is otherwise prevented by the biasing element 290 from rotating back toward its original orientation (e.g., parallel to the longitudinal axis AA).

[0115] refer to Figures 36 to 38 In operation, the plurality of retaining bolts 282 are oriented in an initial unlocked position (e.g., the elongated heads 284 are generally parallel to the longitudinal axis AA). At this point, the solar module 140 is positioned on the support rail 212 such that the lower surface 140b of the support rail 140 abuts the upper surface 216 of the support rail and each of the upwardly turned flanges 232 of the support rail is received within a corresponding bore 150 of the solar module to substantially prevent movement of the solar module 140 relative to the support rail 212 ( Fig.36 and 37 ). With the lower surface 140b of the solar module 140 abutting the upper surface 216 of the support rail 212 and each of the upturned flanges 232 being received within the corresponding bore 150 of the solar module 140, the nut 320 is caused to rotate in the first direction, which causes the elongated head 284 of each of the retaining bolts 282 to rotate toward the center portion of the support rail 212 (e.g., away from each of the opposing first and second side surfaces 214c, 214d) until the outer surface 284a of the elongated head 284 abuts a portion of the upturned flange 232 to prevent further rotation of the elongated head 284. With the elongated head 284 abutting a portion of each upturned flange, the lower surface 284c of each of the elongated heads 284 is disposed above the upper surface 140a of the solar module 140 ( Fig.38 ).

[0116] At this point, each of the nuts 320 is further rotated in the first direction to cause each of the upturned flanges 304a, 304b, and 304c of the retaining washer to be compressed against the lower surface 220 of the support rail and deformed or otherwise flattened against the shape of the lower surface 220 (e.g., generally parallel to the lower surface 220 of the support rail 212). The compression of the upturned flanges 304a, 304b, and 304c causes the upturned flange 304d to protrude an increased distance beyond the upper surface 216 of the support rail 212, and as the elongated head 284 of the retaining bolt 282 is rotated generally 90 degrees (e.g., forming a generally orthogonal angle relative to the longitudinal axis AA), the upturned flange 304d is caused to abut the elongated head 284 of the retaining bolt 282 or otherwise be prevented from rotating back toward its original orientation (e.g., parallel to the longitudinal axis AA) by the biasing element 290 ( Fig.39 and 40 ). Continued rotation of the nut 320 in the first direction causes the lower surface 284 of the retaining bolt 282 to compress against the upper surface 140a of the solar module and couple the solar module 140 to the support rail 212. As can be appreciated, the upwardly turned flange 232 cooperates with the upwardly turned flange 304d to prevent rotation of the elongated head 284 of each retaining bolt 282 in a clockwise or counterclockwise direction, thereby preventing the solar module 140 from moving relative to the support rail 212.

[0117] Although several embodiments of the present disclosure have been shown in the drawings, it is not intended that the present disclosure be limited thereto, as it is intended that the scope of the present disclosure be as broad as the art will allow and the specification be read similarly. Therefore, the above description should not be interpreted as limiting, but merely an exemplification of particular embodiments.

Claims

1. A coupling system for use with a solar tracker, comprising: a support rail defining opposing top and bottom surfaces, the top surface being configured to support a portion of a solar module; and a fastening assembly operably coupled to a portion of the support rail, the fastening assembly including a retaining bolt having an elongated head including opposing top and bottom surfaces extending between opposing first and second end portions, Wherein the bottom surface of the elongated head is offset from the top surface of the support rail to define a gap configured to selectively receive a portion of a solar module therein.

2. The coupling system of claim 1 , further comprising a spring arm operably coupled to the bottom surface of the support rail and including an upturned flange configured to extend beyond the top surface of the support rail.

3. The coupling system of any one of claims 1 or 2, wherein a portion of the solar module includes a retaining groove defined therethrough, the retaining groove being configured to receive a portion of the elongated head of the retaining bolt therein.

4. The coupling system of claim 3 or any preceding claim, wherein the boss of the retaining bolt includes an outer dimension that permits the retaining bolt to slide within the retaining groove of the solar module from a first position in which a portion of the solar module is not received within the gap and a second position in which a portion of the solar module is received within the gap.

5. The coupling system of claim 4 or any preceding claim, wherein the upturned flange of the spring arm is configured to be received within the retaining groove when the solar module is in the second position such that the elongated head cooperates with the upturned flange to prevent movement of the solar module relative to the support rail.

6. A coupling system according to claim 1 or any preceding claim, further comprising a biasing element interposed between the bottom surface of the elongated head and the top surface of the support rail to bias the elongated head away from the top surface of the support rail.

7. The coupling system of claim 6 or any preceding claim, wherein the biasing element is configured to be compressed to adjust the distance between the bottom surface of the elongated head and the top surface of the support rail.

8. A coupling system according to claim 7 or any preceding claim, further comprising a nut threadedly engaged to a portion of the retaining bolt, the nut being configured to compress the biasing element when rotated in a first direction and to enable the biasing element to extend when rotated in a second, opposite direction.

9. A coupling system according to claim 1 or any preceding claim, wherein the retaining bolt includes a boss disposed on the bottom surface of the elongated head, the boss extending from the bottom surface and terminating at a lower surface, the lower surface adjacent a portion of the top surface of the support rail to define the gap.

10. The coupling system of claim 1 or any preceding claim, wherein the elongated head defines a racetrack-shaped profile.

11. A fastening assembly for use with a solar module, comprising: A retaining bolt, the retaining bolt comprising: an elongated head including opposing top and bottom surfaces extending between opposing first and second end portions; and a boss disposed on a portion of the bottom surface of the elongated head and disposed adjacent one of the first end portion and the second end portion, Wherein the bottom surface of the elongated head is offset from a lower surface of the boss to define a gap configured to selectively receive a portion of a solar module therein.

12. The fastening assembly of claim 11, further comprising a spring arm configured to selectively engage a portion of a solar module.

13. The fastening assembly of any one of claims 11 or 12, further comprising a biasing element disposed adjacent the bottom surface of the elongated head and configured to be compressed to alter the size of the gap.

14. The fastening assembly of any one of claims 11 to 13, wherein the boss extends from the bottom surface of the elongated head and terminates at a lower surface, the distance between the bottom surface of the elongated head and the lower surface of the boss defining the size of the gap.

15. The fastening assembly of any one of claims 11 to 14, wherein the elongated head defines a racetrack-shaped profile.

16. A method of coupling a solar module to a support rail, comprising: aligning a retaining groove defined on a portion of the solar module with an elongated head of a retaining bolt, wherein a lower surface of the retaining bolt is offset relative to an upper surface of the support rail to define a gap therebetween; advancing the solar module toward the upper surface of the support rail such that a portion of the elongated head of the retaining bolt is received within the retaining groove; and The solar module is advanced in a first longitudinal direction such that a portion of the solar module is received within the gap, thereby selectively retaining the solar module to the support rail.

17. The method of claim 16, wherein advancing the solar module toward the upper surface of the support rail comprises causing a portion of the solar module to abut a portion of an upturned flange of a spring arm operably coupled to a portion of the support rail and causing the upturned flange to be compressed.

18. The method of any of claims 16 or 17, wherein advancing the solar module in the first longitudinal direction causes the upwardly turned flange of the spring arm to decompress and be received within a portion of the retaining groove.

19. The method of any one of claims 16 to 18, further comprising rotating a nut threadably engaged to a portion of the retaining bolt in a first direction to alter a size of the gap.

20. The method of any one of claims 16 to 19, wherein rotating the nut in the first direction comprises rotating the nut in the first direction to compress a biasing element interposed between the lower surface of the retaining bolt and the upper surface of the support rail, thereby changing the size of the gap.

Images