Photovoltaic panel fixing clamp

Abstract

A fixing clamp for securing photovoltaic panels to a ground-mounted support frame comprising: a base with a first sidewall extending perpendicular therefrom with an perpendicular outward facing lip; a

Description

The present invention relates to a photovoltaic (PV) panel fixing clamp and particularly but not exclusively to a PV panel fixing clamp to secure PV panels to ground mounted solar panel array support frames. BACKGROUND TO THE INVENTION With the UK’s projected electricity demands to increase significantly in the coming decades, The Department of Business, Energy, Industrial Strategy (BEIS) estimates that much of this increased demand will be generated with renewable energy. Of this, solar energy stands to make significant contributions to energy generation. To meet governmental targets of net zero greenhouse emissions by 2035, solar capacity will need to be increased fivefold, to reach the target energy generation from solar of 70GW. Designated solar farms with ground-mounted solar arrays will need to become more widespread to help reach these goals. Installation of ground-mounted solar arrays is labour and time intensive with innovation needed to make the installation of PV panels easier and more efficient to keep up with the increased demand. Currently, clamps are widely used to attach PV panels to the rails of a support frame, which is anchored into the ground. These clamps come in different configurations, with mid- and end-clamps most common. The depth of the clamps corresponds to the PV panel thickness so that when attached, the clamp rests flush against the panel. To secure the clamps and panel to the support frame, a socket head screw is passed through the top of the clamp to a receiving nut on the underside of the frame, through a pre-drilled hole. This standard method of installation requires three people, one to hold the panel in place, one to hold the socket screw head in place with an Allen key to prevent the screw from spinning and one to tighten the nut to fix the clamp and panel into place. With a shortage of skilled workers reported by Solar Energy UK, with 48% of the renewable industry struggling to find skilled labour, requiring multiple people to fit these panels increases the time and cost needed to complete ground-mounted solar array installation. It is an object of the present invention to reduce or substantially prevent the aforementioned problems. STATEMENT OF INVENTION According to the present invention there is provided a photovoltaic (PV) panel fixing clamp for securing PV panels to a ground-mounted support frame, the fixing clamp comprising: a base, a first sidewall extending substantially perpendicular from one edge of the base, and a lip extending away from an upper edge of the sidewall, substantially perpendicular to the sidewall, for engaging over an upper edge of a PV panel in use; one or more apertures provided through the base for receiving screw fixings of a predetermined head size, having at least one flat side, the one or more apertures being positioned proximate the sidewall enabling the flat side of the screw fixing to engage against the sidewall, preventing rotation of the screw fixing; and one or more barb(s) positioned above the base on the interior edge of the sidewall adjacent to the, or each, aperture for retaining the head of the screw fixing in the aperture, once inserted. The base may lie on top of the support frame, adjacent to a PV panel, and may contain one or more apertures for a screw fixing to be inserted to connect the clamp to the underlying support frame. The lip may extend over the upper surface of a PV panel along its edge for securely connecting the PV panels to the support frame. The aperture(s) in the base are positioned advantageously to enable the screw head sides to engage with the, or each, sidewall. This prevents the screw rotating when a nut is tightened on the underside of the clamp to secure the clamp to the support frame, therefore, alleviating the need for an additional labourer to hold the screw head against rotation. The barb(s) positioned on the interior sidewall(s) of the clamp lie over the top of the screw head when inserted. This prevents the screw head from lifting out of the clamp once inserted. Again, this alleviates the need for an additional labourer to hold the screw down in the aperture as a nut is being attached. A second sidewall may extend substantially perpendicular from an opposite edge of the base, thereby forming a channel between the first sidewall, base and second sidewall. One or more barb(s) may be positioned on the second sidewall adjacent to the, or each, aperture, parallel to the barb(s) on the first sidewall. In this embodiment of the invention, the provided barbs on opposing sidewalls are orientated to face one another, narrowing the channel created between the first sidewall, base and second sidewall. These parallel protrusions narrow the diameter of the channel to a width smaller than that of the screw head. This forces the user to apply pressure to the screw fixing when passing the barbs, pressing the sidewalls outwards to enable the screw to enter the aperture. One the screw is inserted, and the screw head rests in the gap between the base and bottom edge of the barbs, the sidewalls return to their original position. This enables the barbs to project over the top of the screw head when inserted, ensuring the screw cannot rise out of the clamp when inserted. Additionally, the barbs limit the need to hold the screw straight in the aperture. A second lip may extend away from the second sidewall, substantially perpendicular to the sidewall, for engaging over an upper edge of a second adjacent PV panel when in use. A second lip allows for two PV panels to be connected to a single fixing clamp. This is advantageous for securing PV panels in the middle of a solar array, reducing the number of clamps needed and ensuring the PV panels are secured close together. The fixing clamp may be provided in substantially any length, with the aperture(s) provided at spaced intervals for engaging with the support frame underneath. The height of the sidewall(s) may be between 20mm and 50mm. The height of the sidewall(s) corresponds with the height of the specific PV panels used, ensuring that the exterior sidewall of the clamp and edge of the PV panel are in full contact. This facilitates correct installation of the PV panels. The width of the base may be 20mm or less. The space for receiving a screw head between the first and second sidewalls may be between 10mm and 15mm, but optimally around 13mm, for example, for receiving a 13mm screw head. The screw head is tightly accommodated within the sidewalls, ensuring that it remains stationary during the solar array installation. The fixing clamp may be constructed by extrusion. Manufacturing the clamp via extrusion ensures the clamp complies with exact specifications in a cost-effective manner. The fixing clamp may be extruded from aluminium. Construction from aluminium reduces the risk of corrosion. Furthermore, the sidewall(s) of the clamp may flex relative to the base, for enabling a screw head to be passed through the barbs, into the aperture. The sidewall(s) ability to flex allows the sidewall(s) to expand outwards when a screw is inserted, allowing for a narrower distance between sidewalls, ensuring the screw head is engaging with the sidewall(s), while not hindering its insertion. The barb(s) may be triangular in form with the bottom of the triangle orientated to face the base of the fixing clamp and the tip of the triangle merging with the sidewall above the bottom. This form acts as a ramp, guiding the screw head past the barb protrusions, until the screw head rests underneath the barb(s). Once inserted, the bottom edge of the barb(s) protrudes over the top of the screw head, preventing the screw lifting out of the clamp. The fixing clamp may have at least one screw fixing provided and said screw may have a hexagonal head for engaging against the first or both the first and second sidewall. One or more sides of the screw head may engage with the, or each, sidewall. This increased surface area of engagement between the screw head and sidewall(s) improves resistance to the rotational force that is applies when tightening the nut on the underside of the clamp to secure the clamp to the support frame. Thus, the screw does not rotate, alleviating the need for an additional person to stabilise the screw head when fastening the clamp. The fixing clamp may come provided with screw fixing already inserted. This would improve ease of installation, removing the need to insert the screw manually. The depth of the screw head may allow the head to sit underneath the barb(s), when inserted in the aperture. In other words, the screw cannot be pushed back out of the aperture. The fixing clamp may be provided with a downward facing ridge positioned at the distal edge of the, or each, lip. The ridge may securely engage against a PV panel. According to the second aspect of the invention, there is provided a method of securing PV panels to a support frame using a fixing clamp of the first aspect of the invention, the method comprising the steps of: positioning the lip of the fixing clamp over the face of the PV panel; aligning the aperture located in the base of the clamp to the corresponding aperture in the support frame; inserting a screw fixing past the barb(s), through the aperture and into the support frame so that the screw head rests in the gap defined between the base, sidewall(s) and the bottom edge of the barb(s); and threading the female thread of a nut onto the corresponding male thread of the screw fixing from the underside of the clamp and support frame, thus securing the clamp to the support frame. According to a third aspect of the invention, there may be provided a method of securing PV panels to a support frame using a fixing clamp of the first aspect of the invention, in which a screw fixing is inserted in the aperture prior to installation. A washer may be utilised under the nut to disperse load to the frame when fastened. According to a further aspect of the invention, there may be provided a ground or roof mounted solar array fitted with one or more fixing clamps according to the first aspect of the invention. BRIEF DESCRIPTION OF THE DRAWINGS For a better understanding of the present invention, and to show more clearly how it may be carried into effect, reference will now be made by way of example only to the accompanying drawings, in which: Figure 1 is a front view of the first embodiment of the fixing clamp; Figure 2 is a top-down view of Figure 1; Figure 3 shows Figure 1 with an inserted socket screw; Figure 4 shows Figure 2 with an inserted socket screw; Figure 5 is a front view of the second embodiment of the fixing clamp with an inserted screw; and Figure 6 is a top-down view of Figure 5 with an inserted screw. DESCRIPTION OF PREFERRED EMBODIMENTS Referring firstly to Figure 1, a fixing clamp for attaching PV panels to a ground-mounted support frame is generally indicated at 10. Common features between the two embodiments (10, 100) of the invention are indicated with the same reference numbers. The fixing clamp is shown ex situ. The first embodiment of the fixing clamp 10 is shown in Figures 1-4 and is formed from a singular member comprising a base 20, a first and second sidewall 16a-b, a first and second barb 18a-b, a first and second lip 12a-b and a first and second ridge 14a-b. When in use the base 20 of the fixing clamp 10 rests on top of a section of a solar array support frame (not shown). The sidewall(s) 16 of the fixing clamp 10 extend upwards perpendicular from the edges of the base, with their height matching the thickness of the relevant PV. The height of the sidewall(s) 16 can range between 20mm and 50mm depending on the type of PV panels used. This allows a PV panel to sit flush against the exterior of the sidewalls 16. The lip 12 of the fixing clamp 10 extends perpendicular outwards from the sidewall 16 to lay on top of the face of a PV panel. In some embodiments, this may be anchored in place by the downward facing ridge 14 positioned at the end of the lip 12 that hooks into a corresponding groove on the face of the PV panel (not shown). One PV panel therefore sits against the fixing clamp 10 on two sides: the exterior of the sidewall and the underside of the lip 12. For the first embodiment of the invention, as seen in Figure 1, the sidewall 16 and lip 14, with corresponding ridge 12, are mirrored on both sides of the base 20, with the lips 12 facing away from the base 20 to form the U-shaped clamp 10. This allows two PV panels to be anchored to the support frame by one clamp 10. In a second embodiment of the invention, shown in Figures 5-6, the fixing clamp 100 is comprised of only one sidewall 16 attached to one edge of the base 20, with all remaining features identical. This forms a Z-shaped clamp 100 that can only anchor one PV panel to the support frame. This type of clamp 100 would be used at the ends of a solar array. Once a PV panel is connected to a clamp 10, the clamp 10 is secured to the support frame of the solar array using a screw fixing 24 threaded through an aperture 22, for example, on the longitudinal midline of the base 20 to a corresponding aperture in the support frame, shown in Figure 2. The aperture 22 is positioned adequately away from the edge of the base 20 so that when tightened the pressure exerted by the screw 24 does not cause any weaknesses in the base 20. A screw fixing 24 is inserted into the aperture (Figures 3 and 5) and through the corresponding aperture, in the support frame, joining the clamp 10, 100 (and attached PV panel(s)) to the support frame. The screw fixing 24 is secured by threading the male thread 26 of the screw fixing 24 into the female thread of a nut (not shown) on the underside of the clamp 10. During insertion into the aperture 22, the head 28 of the screw fixing 24 is guided past the interior of the sidewalls 18. In the first embodiment of the invention, this necessitates the two sidewalls 16 to slightly spread apart to allow adequate space for the head 28 to enter. The channel created between the first sidewall 16, base 20 and second sidewall 16 is between 10mm and 15mm is width and optimally 13mm wide. This channel is not provided in the second embodiment of the invention as only one sidewall 16 is present. In both embodiments the head 28 is pushed past the barb(s) 18 positioned on the interior sidewall(s) 16. Each sidewall 16 is provided with one barb 18 that spans the entire length of the sidewall 16 at a consistent height above the base 20. The barbs 18 are positioned sufficiently above the base 20 to allow space for the head 28 of a screw fixing 24 of a predetermined size to rest there when inserted into the aperture 22. The barbs 18 have a triangular cross-section and protrude from the interior of the sidewalls 16 such that the flat bottom of the triangle is facing the base 20 and the tip of the triangle faces upwards and merges with the sidewalls 16 above the flat bottom. The flat bottom of the barb 18 protrudes over the edge of the screw fixing 24 head 28 once inserted, preventing the screw fixing 24 from moving upwards out of the gap created. This is clearly shown in Figures 4 and 6 where the interior edge of the barb(s) 18 overlaps with the depicted screw fixing 24 head 28. The screw fixing 24 is likewise unable to move downwards as the diameter of the aperture 22 is too narrow to accommodate the head 28. Thus, the screw fixing 24 is captured within the fixing clamp 10 once inserted. The head 28 of the screw fixing 24 is hexagonal in shape allowing one or more of the flat edges to rest flush against the interior of the sidewall(s) 16. In the first embodiment of the invention, two edges of the head 28 rest against the sidewalls 16 (Figure 3) and in the second embodiment of the invention only one edge of the head 28 rests against the sidewall 16 (Figure 5) as this embodiment only comprises one sidewall 16. In both embodiments having a flat edge on the screw fixing’s 24 head 28 increases the surface area contact between the head 28 and sidewall(s) 16. This prevents the head 28 from rotating when a nut is threaded onto the male threads 26 of the screw fixing 24. Therefore, the screw fixing 24 is captured, unable both to move upwards or downwards out of the fixing clamp 10 due to the barb(s) 18 or rotate within the space created between the barb(s) 18 and base 20 due to the hexagonal nature of the head 28. This greatly improves the ease of installation of the described invention, improving 5 efficiency and limiting the number of skilled workers needed to install the overall solar array. Both embodiments of the fixing clamp 10, 100 can be made by extrusion, preferably in aluminium. The embodiments described above are provided by way of example only, and various 10 changes and modifications will be apparent to persons skilled in the art without departing from the scope of the present invention as defined by the appended claims.

Claims

1. A fixing clamp for securing photovoltaic (PV) panels to a ground-mounted support frame, the fixing clamp comprising:a base, a first sidewall extending substantially perpendicular from one edge of the base, and a lip extending away from an upper edge of the sidewall, substantially perpendicular to the sidewall, for engaging over an upper edge of a PV panel when in use;one or more apertures provided through the base for receiving screw fixings of a predetermined head size, having at least one flat side, the one or more apertures being positioned proximate the sidewall enabling the flat side of the screw fixing to engage against the sidewall, preventing rotation of the screw fixing; andone or more barb(s) positioned above the base on the interior edge of the sidewall adjacent to the, or each, aperture for retaining the head of the screw fixing in the aperture, once inserted.

2. A fixing clamp as claimed in claim 1, in which a second sidewall extends substantially perpendicular from an opposite edge of the base, thereby forming a channel between the first sidewall, base and second sidewall.

3. A fixing clamp as claimed in claim 2, in which one or more barb(s) are positioned on the second sidewall adjacent to the, or each, aperture, parallel to the barb(s) on the first sidewall.

4. A fixing clamp as claimed in claim 2 or claim 3, in which a second lip extends away from the second sidewall, substantially perpendicular to the sidewall, for engaging over an upper edge of a PV panel when in use.

5. A fixing clamp as claimed in any preceding claim, in which the fixing clamp can be provided in substantially any length, with the aperture(s) provided at spaced intervals for engaging with the support frame underneath.

6. A fixing clamp as claimed in any preceding claim, in which the height of the sidewall(s) is between 20mm and 50mm.

7. A fixing clamp as claimed in claim 6, in which the width of the base is 20mm or less.

8. A fixing clamp as claimed in any preceding claim, in which the space for receiving a screw head between the first and second sidewalls is between 10mm and 15mm.

9. A fixing clamp as claimed in any preceding claim, in which the fixing clamp is constructed by extrusion.

10. A fixing clamp as claimed in claim 9, in which the fixing clamp is extruded from aluminium.

11. A fixing clamp as claimed in any preceding claim, in which the sidewall(s) of the clamp can flex relative to the base, for enabling a screw head to be passed through the barbs, into the aperture.

12. A fixing clamp as claimed in any preceding claim, in which the barb(s) are triangular in form with the bottom of the triangle orientated to face the base of the fixing clamp and the tip of the triangle merging with the sidewall above the bottom.

13. A fixing clamp as claimed in any of the preceding claims, in which at least one screw fixing is provided and said screw has a hexagonal head for engaging against the first or both the first and second sidewall.

14. A fixing clamp as claimed in claim 13, in which the depth of the screw head allows the head to sit underneath the barb(s), when inserted in the aperture.

15. A fixing clamp as claimed in any of the proceeding claims, in which a downward facing ridge is positioned at the distal edge of the, or each, lip.

16. A method of securing PV panels to a support frame using the fixing clamp as claimed in any one of claims 1-15, the method comprising the steps of:positioning the lip of the fixing clamp over the face of the PV panel;aligning the aperture located in the base of the clamp to the corresponding aperture in the support frame;inserting a screw fixing past the barb(s), through the aperture and into the support frame so that the screw head rests in the gap defined between the base, sidewall(s) and the bottom edge of the barb(s); andthreading the female thread of a nut onto the corresponding male thread of the screw fixing from the underside of the clamp, securing the clamp to the support frame.

17. A method as claimed in claim 16, in which a screw fixing is inserted in the aperture 5 prior to installation.

18. A method as claimed in claim 16 or claim 17, in which a washer is threaded onto the body of the screw on the underside of the fixing clamp prior to the nut being tightened.

19. A ground or roof mounted solar array fitted with one or more fixing clamps as 10 claimed in any of claims 1 to 15.AMENDMENTS TO THE CLAIMS HAVE BEEN FILED AS FOLLOWS24 01 25CLAIMS1. A fixing clamp for securing photovoltaic (PV) panels to a ground-mounted support frame, the fixing clamp comprising:a base, a first sidewall extending substantially perpendicular from one edge of 5 the base, and a lip extending away from an upper edge of the sidewall, substantially perpendicular to the sidewall, for engaging over an upper edge of a PV panel when in use;one or more apertures provided through the base , the one or more apertures being positioned proximate the sidewall;10 one or more screw fixings of a predetermined head size disposed in the one or more apertures, having at least one flat side which engages against the sidewall to prevent rotation of the screw fixing; andone or more barb(s) positioned above the base on the interior edge of the sidewall adjacent to the, or each, aperture for retaining the head of the screw 15 fixing in the aperture, once inserted.

2. A fixing clamp as claimed in claim 1, in which a second sidewall extends substantially perpendicular from an opposite edge of the base, thereby forming a channel between the first sidewall, base and second sidewall.

3. A fixing clamp as claimed in claim 2, in which one or more barb(s) are positioned 20 on the second sidewall adjacent to the, or each, aperture, parallel to the barb(s) on the first sidewall.

4. A fixing clamp as claimed in claim 2 or claim 3, in which a second lip extends away from the second sidewall, substantially perpendicular to the sidewall, for engaging over an upper edge of a PV panel when in use.25 5. A fixing clamp as claimed in any preceding claim, in which the fixing clamp can beprovided in substantially any length, with the aperture(s) provided at spaced intervals for engaging with the support frame underneath.

6. A fixing clamp as claimed in any preceding claim, in which the height of the sidewall(s) is between 20mm and 50mm.24 01 257. A fixing clamp as claimed in claim 6, in which the width of the base is 20mm or less.

8. A fixing clamp as claimed in any preceding claim, in which the space for receiving a screw head between the first and second sidewalls is between 10mm and 15mm.5 9. A fixing clamp as claimed in any preceding claim, in which the fixing clamp isconstructed by extrusion.

10. A fixing clamp as claimed in claim 9, in which the fixing clamp is extruded from aluminium.

11. A fixing clamp as claimed in any preceding claim, in which the sidewall(s) of the 10 clamp can flex relative to the base, for enabling a screw head to be passed through the barbs, into the aperture.

12. A fixing clamp as claimed in any preceding claim, in which the barb(s) are triangular in form with the bottom of the triangle orientated to face the base of the fixing clamp and the tip of the triangle merging with the sidewall above the bottom.15 13. A fixing clamp as claimed in any of the preceding claims, in which at least onescrew fixing is provided and said screw has a hexagonal head for engaging against the first or both the first and second sidewall.

14. A fixing clamp as claimed in claim 13, in which the depth of the screw head allows the head to sit underneath the barb(s), when inserted in the aperture.20 15. A fixing clamp as claimed in any of the proceeding claims, in which a downwardfacing ridge is positioned at the distal edge of the, or each, lip.

16. A method of securing PV panels to a support frame using the fixing clamp as claimed in any one of claims 1-15, the method comprising the steps of:positioning the lip of the fixing clamp over the face of the PV panel;25 positioning the exterior sidewall(s) of the fixing clamp to abut against the entirewidth of the PV panel;aligning the aperture located in the base of the clamp to the corresponding aperture in the support frame;inserting a screw fixing past the barb(s), through the aperture and into the support frame so that the screw head rests in the gap defined between the base, sidewall(s) and the bottom edge of the barb(s); andthreading the female thread of a nut onto the corresponding male thread of the 5 screw fixing from the underside of the clamp, securing the clamp to the supportframe.

17. A method as claimed in claim 16, in which a screw fixing is inserted in the aperture prior to installation.

18. A method as claimed in claim 16 or claim 17, in which a washer is threaded onto 10 the body of the screw on the underside of the fixing clamp prior to the nut being tightened.

19. A ground or roof mounted solar array fitted with one or more fixing clamps as claimed in any of claims 1 to 15.24 01 251515

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