Wire clamp for solar mounting installations

Abstract

A wire clamp may include: a bottom portion having a first bottom channel portion and a second bottom channel portion, the first and second bottom channel portions configured to receive one or more wires; a top portion having a first top channel portion and a second top channel portion, the first and second top channel portions configured to cooperate with the first and second bottom channel portions, respectively, to form a first channel and a second channel; and a center portion having an aperture configured to receive and align a fastener, thereby securing the one or more wires in the wire clamp. A system and a method are also disclosed.

Description

Attorney Docket No. 09549-2504162WIRE CLAMP FOR SOLAR MOUNTING INSTALLATIONSCROSS-REFERENCE TO RELATED APPLICATION

[0001] This application claims priority to U.S. Provisional Patent Application No. 63 / 692,490 filed September 9, 2024, the disclosure of which is hereby incorporated by reference in its entirety.BACKGROUND OF THE INVENTIONField of the Invention

[0002] This disclosure relates generally to a wire clamp and, more particularly, to a wire clamp capable of being applied to a rail in a solar panel system to organize and arrange the wires running through the solar panel array.Description of Related Art

[0003] Various wire conduits, clips, and clamps have been developed to route and protect wires throughout industrial spaces. However, these apparatuses tend to bunch and clamp wires together in such a way that affects their lifespan. They also fail to provide easy access to individuals trying to move the wires for one purpose or another. Thus, there exists a need to provide a mountable wire clamp that can organize wires in such a way that prolongs their lifespan and makes them easier to access or move when organized.

[0004] Common methods for managing wires include using zip ties that are commonly made of plastic and have a lifespan that is shorter than the service life of the wires and equipment they are used to support. This can lead to failure of the wire management causing sagging wires that can contact surfaces that can damage the wires and wire insulation, such as sharp edges and high heat surfaces. Another common wire management device is wire clips that are typically made of stainless steel, and while these do commonly have sufficient lifespan, they have other limitations which make them less desirable. They often require the use of many clips which can be expensive, and the clips can only manage the wires in a single direction, most commonly parallel to the rail or member the clip is attached to. Wires are sometimes managed in such a way that the wire contacts the sharp edges of rails or other cut edges of various materials and structures. The limitations of current wire management solutions create situations where installers are unable to maintain the minimum required bend radiuses for wires. Thus, there exists a need to provide affordable, durable, simple, and easy to install6742193.DOCX 1Attorney Docket No. 09549-2504162 clamps that can manage single or multiple wires in unlimited direction relative to the structural members the wires are connected to.SUMMARY OF THE INVENTION

[0005] One non-limiting embodiment of the present disclosure may be a wire clamp including a bottom portion comprising: a first bottom channel portion and a second bottom channel portion, the first and second bottom channel portions configured to receive one or more wires; a top portion comprising: a first top channel portion and a second top channel portion, the first and second top channel portions configured to cooperate with the first and second bottom channel portions, respectively, to form a first channel and a second channel; and a center portion comprising an aperture configured to receive and align a fastener, thereby securing the one or more wires in the wire clamp.

[0006] Another non-limiting embodiment of the present disclosure may be a wire routing system comprising: a rail; and a wire clamp comprising: a bottom portion comprising: a first bottom channel portion and a second bottom channel portion, the first and second bottom channel portions configured to receive one or more wires; a top portion comprising: a first top channel portion and a second top channel portion, the first and second top channel portions configured to mate with the first and second bottom channel portions, respectively, to form a first channel and a second channel; and a center portion comprising an aperture configured to receive and align a fastener therethrough, thereby mounting the wire clamp to the rail.

[0007] Another non-limiting embodiment of the present disclosure may be a method of clamping wires comprising the steps of: placing wires within a first wire channel of a bottom portion of a wire clamp, the bottom portion comprising a first aperture, placing wires within a second wire channel of the bottom portion of the wire clamp, aligning a second aperture defined by a top portion of the wire clamp over the first aperture, and extending a fastener through the second aperture and the first aperture, thereby clamping the top portion to the bottom portion, wherein the wire clamp further comprises a center portion having a knuckle that is integral to and connects the bottom and top portions of the wire clamp, thereby forming a single part.

[0008] The invention may also be summarized according to the following clauses:

[0009] Clause 1. A wire clamp comprising: a bottom portion comprising: a first bottom channel portion and a second bottom channel portion, a top portion comprising: a first top channel portion and a second top channel portion, the first and second top channel portions configured to cooperate with the first and second bottom channel portions, respectively, to form6742193.DOCX 2Attorney Docket No. 09549-2504162 a first wire channel and a second wire channel; and a center portion comprising an aperture configured to receive a fastener for securing the wire clamp to a structure.

[0010] Clause 2. The wire clamp of clause 1 , wherein the center portion further comprises a knuckle that is integral to and connects the bottom and top portions, thereby forming a single part.

[0011] Clause 3. The wire clamp of clause 1 , wherein the first bottom channel portion and second bottom channel portion include at least one or more bottom flanges extending from first and second bottom channel portions.

[0012] Clause 4. The wire clamp of clause 3, wherein the first top channel portion and second top channel portion include at least one or more top flanges extending from first and second top channel portions.

[0013] Clause 5. The wire clamp of clause 4, wherein the bottom flanges and top flanges extend away from the bottom portion and top portion, respectively, and form an angle of divergence of between about 25-65 degrees.

[0014] Clause 6. The wire clamp of any of clauses 1-5, wherein the bottom portion includes one or more ridges in the first and second bottom channel portions for gripping the one or more wires.

[0015] Clause 7. The wire clamp of clause 6, wherein the top portion includes one or more ridges in the first and second top channel portions for gripping the one or more wires.

[0016] Clause 8. The wire clamp of clause 7, wherein the ridges in the bottom portion and ridges in the top portion are staggered from each other so they do not grip the wire at the same location.

[0017] Clause 9. The wire clamp of any of clauses 1-8, wherein the one or more wires comprise one or more of photovoltaic (PV) wires, homeruns, trunk cables, or other electrical wires.

[0018] Clause 10. The wire clamp of any of clauses 1-9, wherein the first and second wire channels are the same size.

[0019] Clause 11. The wire clamp of any of clauses 1-9, wherein the first and second wire channels are different sizes.

[0020] Clause 12. The wire clause of any of clauses 1-11, wherein the aperture of the center portion comprises a first aperture formed in the bottom portion and a second aperture formed in the top portion.

[0021] Clause 13. The wire clamp of clause 12, wherein the bottom portion comprises an at least partially elliptical first barrier extending from the first bottom channel portion around6742193.DOCX 3Attorney Docket No. 09549-2504162 the first aperture and an at least partially elliptical second barrier extending from the second bottom channel portion around the second aperture.

[0022] Clause 14. The wire clamp of clause 12, wherein the top portion comprises a third and fourth aperture, wherein the bottom portion further comprises a first post and a second post extending from the bottom portion, and wherein the first post and the second post are configured to be received within the third aperture and the fourth aperture.

[0023] Clause 15. The wire clamp of clause 14, wherein the first post and the second post are disposed symmetrically about the first aperture.

[0024] Clause 16. The wire clamp of any of clauses 1-15, wherein the top portion is at least partially arched about the bottom portion.

[0025] Clause 17. The wire clamp of any of clauses 1-16, wherein the fastener comprises a t-nut, a cap screw, a t-bolt, a square bolt, or a portion of a fastener assembly, or any combination thereof.

[0026] Clause 18. The wire clamp of any of clauses 1-19, wherein the structure is a rail.

[0027] Clause 19. The wire clamp of clause 18, wherein the wire clamp is configured to be parallel to, perpendicular to, or at an angle relative to the rail in the rail assembly.

[0028] Clause 20. The wire clamp of clause 18, wherein the wire clamp is configured to sit on top of or partially within an open channel on top of the rail.

[0029] Clause 21. A wire clamp comprising: a bottom portion comprising a bottom channel portion, a planar bottom center portion and an opening in the bottom center portion; a top portion comprising a contoured top channel portion, a planar top center portion and an opening in the center portion which corresponds to the opening in the bottom center portion; a loop section connected to the bottom center portion and the top center portion; the bottom channel portion and the top channel portion cooperating to define a wire channel; each of the bottom portion and the top portion having a contoured flange, the contoured flanges opposing one another and having lips which diverge in a direction opposite the loop section; the contoured flanges being resilient and separable to provide a clearance for manual insertion of at least one wire between the lips and into the wire channel.

[0030] Clause 22. The wire clamp of clause 21, wherein the openings in the center portions define a slot for receiving a fastener.

[0031] Clause 23. The wire clamp of clause 22, wherein the slot is open-ended.

[0032] Clause 24. The wire clamp of any of clauses 21-23, wherein the opposed contoured flanges are configured to resiliently come into contact with one another after insertion of the at least one wire.6742193.DOCX 4Attorney Docket No. 09549-2504162

[0033] Clause 25. The wire clamp of any of clauses 21-24, wherein the bottom channel portion is planar.

[0034] Clause 26. The wire clamp of any of clauses 21-25, wherein the clamp is of integral construction and is made from a resilient material.

[0035] Clause 27. The wire clamp of clause 26, wherein the material is sheet metal.

[0036] Clause 28. A wire routing system comprising: a rail with a longitudinal top opening; a coupling engageable with the top opening; and a wire clamp comprising: a bottom portion comprising: at least one bottom channel portion configured to receive one or more wires; a top portion comprising: at least one top channel portion configured to mate with a corresponding one of the at least one bottom channel portion to form at least one wire channel; and a body portion comprising an aperture configured to receive and align a fastener therethrough, thereby mounting the wire clamp and the coupling to the rail.

[0037] Clause 29. A method of clamping wires in a solar panel system comprising the steps of: securing a wire clamp to a rail, which rail is supporting one or more solar panels; the wire clamp having a top portion and a bottom portion defining a wire channel, and opposed flanges adjacent the wire channel; placing at least one wire into contact with the opposed flanges with a longitudinal axis of the wire being approximately normal to a longitudinal axis of the wire clamp; pressing the wire to separate the flanges and provide a clearance between the flanges; and further pressing the wires through the clearance and into the wire channel.BRIEF DESCRIPTION OF THE DRAWINGS

[0038] Fig. 1 is a perspective top view of a wire clamp according to one non-limiting embodiment of the present disclosure;

[0039] Fig. 2 is a perspective bottom view of the wire clamp of Fig. 1;

[0040] Fig. 3 includes various views of a top portion of the wire clamp of Fig. 1;

[0041] Fig. 4 includes various views of a bottom portion of the wire clamp of Fig. 1;

[0042] Figs. 5 A and 5B are perspective views of a fastener assembly according to one nonlimiting embodiment of the present disclosure;

[0043] Figs. 6A-6E are various views of components of a fastener assembly according to one non-limiting embodiment of the present disclosure;

[0044] Figs. 7A-7G are various views of components of a wire clamp according to one nonlimiting embodiment of the present disclosure;6742193.DOCX 5Attorney Docket No. 09549-2504162

[0045] Fig. 8A shows a perspective view of two primary components of a wire clamp according to one non-limiting embodiment of the present disclosure;

[0046] 8B shows various views of a top portion of a wire clamp of FIG 8A according to one non-limiting embodiment of the present disclosure;

[0047] 8C shows various views of a bottom portion of the wire clamp according to one nonlimiting embodiment of the present disclosure;

[0048] Figs. 9A-9E are various views of a wire clamp according to one non-limiting embodiment of the present disclosure;

[0049] Figs. 10A-10D are various views of a wire clamp according to one non-limiting embodiment of the present disclosure oriented perpendicularly to a rail;

[0050] Figs. 11A and 11B are perspective views of a wire clamp according to one nonlimiting embodiment of the present disclosure oriented at different angles to a rail;

[0051] Figs. 12A-12C are various views of a wire clamp according to one non-limiting embodiment of the present disclosure mounted to a rail;

[0052] Figs. 13A-13D are various views of a wire clamp according to one non-limiting embodiment of the present disclosure mounted to a rail;

[0053] Figs. 14A and 14B are various views of a wire clamp according to one non-limiting embodiment of the present disclosure mounted to a rail;

[0054] Figs. 15A and 15B are various views of an exemplary rail that may be used with a wire clamp according to one non-limiting embodiment of the present disclosure; and

[0055] Fig. 16 is a flowchart for a method according to the present disclosure.DETAILED DESCRIPTION OF THE INVENTION

[0056] As used herein, the singular forms of “a,” “an,” and “the” include plural referents unless the context clearly dictates otherwise.

[0057] Spatial or directional terms, such as “left,” “right,” “inner,” “outer,” “above,” “below,” and the like, relate to the disclosure as shown in the drawing figures and are not to be considered as limiting as the disclosure can assume various alternative orientations.

[0058] For purposes of the description hereinafter, the terms “upper,” “lower,” “right,” “left,” “vertical,” “horizontal,” “top,” “bottom,” “lateral,” “longitudinal,” and derivatives thereof shall relate to the disclosure as it is oriented in the figures. However, it is to be understood that the disclosure may assume alternative variations and step sequences, except where expressly specified to the contrary. It is also to be understood that the specific devices and processes illustrated in the attached drawings and described in the following specification6742193.DOCX 6Attorney Docket No. 09549-2504162 are simply exemplary aspects of the disclosure. Hence, specific dimensions and other physical characteristics related to the aspects disclosed herein are not to be considered as limiting.

[0059] The terms “first,” “second,” and the like are not intended to refer to any particular order or chronology, but refer to different conditions, properties, or elements.

[0060] The term “at least” is synonymous with “greater than or equal to.”

[0061] The term “includes” is synonymous with “comprises.”

[0062] The present disclosure is directed, in general, to a wire clamp 10 designed to be mounted to a rail R and used to organize and arrange wires in various industrial environments, such as in a solar panel array. Certain aspects of the wire clamp 10 are shown throughout the Figures, with different embodiments designated by wire clamps 310, 410, 510, etc.

[0063] With reference to Figs. 1-4, the wire clamp 10 includes a bottom portion 12 and a top portion 14. The bottom portion 12 and top portion 14 are joined together via a knuckle 48. Slot 46 may receive a fastener. Any suitable fasteners may be used including, screws, bolts or other fastening means to secure clamp 10 to a structure, as described below. Both the bottom portion 12 and the top portion 14 are generally rectangular and complementary in shape so that the portions 12, 14, when connected via the fastener, define channels 32A, 32B for routing and clamping wires W therethrough. It is understood that the bottom portion 12 and the top portion 14 may take other shapes, so long as they fit together to define a channel or channels for the wires W.

[0064] With reference to Figs. 1-2 and 4, the bottom portion 12 will now be described. The bottom portion 12 includes a first bottom channel portion 20A and a second bottom channel portion 20B. As shown, the first bottom channel portion 20A and second bottom channel portion 20B are located on opposing sides of a center portion 40.

[0065] In some non-limiting aspects or embodiments, first bottom channel portion 20A and second bottom channel portion 20B are about the same size. This may be desirable in situations where the wire clamp 10 is used to clamp similar types of wire W in both channels 32A, 32B. In other non-limiting aspects or embodiments, the first bottom channel portion 20A and second bottom channel portion 20B are different sizes. This may be desirable in situations where the wire clamp 10 is used to clamp different types or sizes of wire in channels 32A, 32B.

[0066] First bottom channel portion 20A and second bottom channel portion 20B may be in communication with flanges 24A, 24B, respectively. As shown, flange 24A extends proximate to a side wall 22 A of first bottom channel portion 20 A and flange 24B extends proximate to a sidewall 22B of second bottom channel portion 20B. The flanges 24A and 24B are angled downward relative to the bottom portion 12.6742193.DOCX 7Attorney Docket No. 09549-2504162

[0067] In some non-limiting aspects or embodiments, first bottom channel portion 20A and second bottom channel portion 20B include ridges 34 (not all labeled for clarity). The ridges 34 provide a corrugated surface on first bottom channel portion 20A and second bottom channel portion 20B that can help align the wires W within the channels 32A, 32B. The corrugation of the ridges 34 also creates some friction that helps retain the wires W in their specific location within the channels 32A, 32B.

[0068] In some non-limiting aspects or embodiments, the wires W received by the first and / or second channel portions 20A, 20B may include photovoltaic (PV) wires, trunk wires, or any other electrical wires being used in accordance with a solar panel assembly system.

[0069] With reference to Figs. 1-3, the top portion 14 will now be described. The top portion 14 includes a first top channel portion 20C and a second top channel portion 20D. As shown, the first top channel portion 20C and second top channel portion 20D are located on opposing sides of center portion 40.

[0070] Similar to the bottom channel portions 20A, 20B, in some non-limiting aspects or embodiments, first top channel portion 20C and second top channel portion 20D are about the same size. This may be desirable in situations where the wire clamp 10 is used to clamp similar types of wire W in both channels 32A, 32B. In other non-limiting aspects or embodiments, the first top channel portion 20C and second top channel portion 20D are different sizes. This may be desirable in situations where the wire clamp 10 is used to clamp different types or sizes of wire W in channels 32 A, 32B. The first top channel portion 20C and the second top channel portion 20D may be contoured.

[0071] First top channel portion 20C and second top channel portion 20D may be in communication with flanges 24C, 24D, respectively. As shown, flange 24C extends proximate to a sidewall 22C of first top channel portion 20C and flange 24D extends proximate to a sidewall 22D of second top channel portion 20D. The flanges 24C and 24D are angled upward relative to the top portion 14.

[0072] In some non-limiting aspects or embodiments, first top channel portion 20C and second top channel portion 20D include ridges 34 (not all labeled for clarity). The ridges 34 provide a corrugated surface on first top channel portion 20C and second top channel portion 20D that can help align the wires W within the channels 32A, 32B. The corrugation of the ridges 34 also creates some friction that helps retain the wires W in their specific location within the channels 32A, 32B.

[0073] In some non-limiting aspects or embodiments, the ridges 34 in the top channel portions 20C, 20D are staggered from any ridges 34 in the bottom channel portions 20A, 20B,6742193.DOCX 8Attorney Docket No. 09549-2504162 so they do not grip the wire(s) W at the same location along the length of the wire(s) W. In some embodiments, the top channel portions 20C, 20D and bottom channel portions 20A, 20B have a different number of ridges 34. For example, as shown in Fig. 1, it can be seen that there are two ridges 34 located on top portion 14 and in Fig. 2, it can be seen that there are three ridges 34 located on bottom portion 12. While not shown, it is envisioned that the same number or different number of ridges 34 may be used in top channel portions 20C, 20D and / or bottom channel portions 20A, 20B.

[0074] The shape and sizing of sets of ridges 34 allow for a variety of wires W to be gripped and secured within the wire channels 32A, 32B. The arrangement shown also allows for wires W of different sizes to be received and secured within the wire channels 32 A, 32B.

[0075] Still referring to Figs. 1-4, the wire clamp 10 includes center portion 40. Center portion 40 is located in between channels 32A, 32B. In some non-limiting aspects of embodiments, center portion 40 includes an aperture or slot 46 and a top body portion 44 and a bottom body portion 42. It should be appreciated that the aperture or slot 46 may take any desired shape, such as a hole, a straight slot, a curved or bent slot, combinations thereof, etc. In some non-limiting aspects or embodiments, knuckle 48 is integral to both top body portion 44 and bottom body portion 42 and connects these portions so that wire clamp 10 is a single part.

[0076] It should be appreciated that top body portion 44 is located in between and separates top channel portions 20C and 20D. Similarly, bottom body portion 42 is located in between and separates bottom channel portions 20A and 20B. Therefore, while center portion 40 has been described as separate from top portion 14 and bottom portion 12, top body portion 44 may be considered to be an extension of top portion 14 and bottom body portion 42 may be considered to be an extension of bottom portion 12.

[0077] In some non-limiting aspects or embodiments, the first bottom channel portion 20A may be coplanar with the second bottom channel portion 20B. The bottom body portion 42 may be coplanar with the first bottom channel portion 20A and the second bottom channel portion 20B. The top body portion 44 may also be planar.

[0078] In some non-limiting aspects or embodiments, knuckle 48 has a flat end section 48A and a curved or curled portion 48B. The curved or curled portion 48B may be thought of as a hinge or spring element that allows the top portion 14 and bottom portion 12 of wire clamp 10 to be aligned with one another.

[0079] It should be appreciated that top portion 14 and bottom portion 12 are designed to cooperate with each other, thereby forming two partially enclosed channels 32A, 32B when6742193.DOCX 9Attorney Docket No. 09549-2504162 the top channel portions 20C and 20D align with bottom channel portions 20A and 20B. For example, the top portion 14 may be arched over the bottom portion 12, such that sidewalls 22A, 22B of the bottom portion 12 come into contact with, abut, or connect to sidewalls 22C, 22D of the top portion 14. This shape allows for the wires W to fit snugly and safely within the channels 32A, 32B when the top portion 14 is mated with and connected to the bottom portion 12.

[0080] Additionally, as provided above, flanges 24A and 24B are angled downward relative to the bottom portion 12 and flanges 24C and 24D are angled upward relative to the top portion 14. When the top portion 14 is aligned and on top of bottom portion 12, the flanges 24A and 24C cooperate with each other and flanges 24B and 24D cooperate with each other. These flange sets, 24A, 24C and 24B, 24D each form an angle of divergence A of between about 25- 65 degrees. This clearance creates a mouth or opening that can assist in guiding wires W into the channels 32A, 32B and in separating the bottom portion 12 and the top portion 14 to allow the wires W to enter into the channels 32A, 32B.

[0081] In some embodiments, the wire clamp 10 and in other clamps described herein, the flanges allow a user to open the clamp 10 by gripping them and separating them from each other. The clamp 10 itself may “spring” open due to the geometry of the clamp 10 and / or the knuckle 48 when a user is separating the flanges to insert the wire(s) into the channels 32A, 32B. In some embodiments, the wire(s) W are inserted into the clamp 10 by pulling the wire(s) against the flanges, this force causing the flanges to open and the wire(s) W to be received in the channels 32A, 32B. However, once a user releases the flanges and / or the wire(s) W are received in the channels 32A, 32B, they serve to “spring” close clamp 10 such that the wire(s) are retained while the clamp 10 is being tightened or mounted to a rail R.

[0082] In order to secure the wires W within wire clamp 10, a fastener (not shown) is received into the aperture or slot 46 of center portion 40. The fastener may be a screw, a bolt, or any suitable means for tightening center portion 40 such that top body portion 44 and a bottom body portion 42 abut each other and / or top portion 14 and bottom portion 12 abut each other. In some non-limiting aspects or embodiments, the top portion 14 and bottom portion 12 engage or mate with each other when the fastener is tightened.

[0083] Turning now to Fig. 5A, a perspective view of a fastener assembly 110 according to one non-limiting embodiment of the present disclosure is shown. Fastener assembly 110 includes a fastener member 104 having a head 114. Fastener member 104 includes an at least partially threaded shank 116 configured to threadingly engage with a threaded opening of a nut member 120 or other fastening components, such as washer 118. As shown, the nut member6742193.DOCX 10Attorney Docket No. 09549-2504162120 is a flanged nut, with the washer 118 being the flange portion of the nut. In other embodiments, the washer 118 may be a separate unthreaded component.

[0084] In some non-limiting aspects or embodiments, such as shown in Fig. 5B, fastener member 104 may include a resistance patch region 166A on the threaded shank 116, which may serve to operate as a positioning mechanism so that rotation of the nut to tighten the fastener assembly 110 onto the rail R rotates the head 114 of the threaded shank 116 into the proper orientation for engagement with the rail R. In some non-limiting aspects or embodiments, the head 114 is shaped like a square or rectangle 164. Additionally, as shown in Figs. 12B and 14C, the fastener assembly 110 may be inserted such that the head 114 is upside down and the nut is placed on the threaded shank 116 above the clamp 10.

[0085] Turning now to Figs. 6A-6E, various views of components of a fastener assembly 200 according to non-limiting embodiments of the present disclosure is shown. In some nonlimiting embodiments, fastener assembly 200 may also be referred to as a module-level power electronics (MLPE) mount assembly 200.

[0086] Details of the MLPE mounting assembly 200 in accordance with an aspect of the present disclosure are shown. MLPE mounting assembly 200 includes an upper mounting support 220, a lower nut member 230, and a fastener member 206. The upper mounting support 220 includes a pair of opposing support wings 222A, 222B extending from a central portion 223. In some non-limiting aspects or embodiments, the support wings 222A, 222B are configured to provide a relatively large support surface on an underside of an item to be mounted. Furthermore, the support wings 222A, 222B are configured to fold upwards via a respective living hinge 229 A, 229B, thereby allowing support wings 222A, 222B to act as a handle or grip for eased installation of the MLPE mounting assembly 200. That is, the folded up support wings 222A, 222B allow a user to hold the mounting assembly 200, align the mounting assembly 200 in a first orientation, insert the mounting assembly 200 into the rail opening and into a first position within the rail, and rotate the MLPE mounting assembly 200 into a second position within the rail.

[0087] A through-hole 226 is provided in the central portion 223 to allow a threaded shank 212 of the fastener member 206 to pass therethrough. Additionally, between the opposing support wings 222A, 222B, opposing edge regions of the central portion 223 extend outwardly from the central portion 223 and include support tabs 224A, 224B. In some non-limiting aspects or embodiments, when the mounting assembly 200 is in a second position, these support tabs 224A, 224B may rest atop the ledge surfaces of the rail, regardless of whether the MLPE mounting assembly 200 is in a tightened or untightened state.6742193.DOCX 11Attorney Docket No. 09549-2504162

[0088] The upper mounting support 220 also includes a pair of deflectable, downwardly- extending clips 226A, 226B, wherein the clips 226A, 226B are configured to releasably engage with respective notches 231 A, 23 IB of the lower nut member 230. The clips 226A, 226B include downwardly extending resilient tabs or flanges, which flanges include inwardly extending lips 227A, 227B. As the upper mounting support 220 is pressed onto the lower nut member 230, the clips 226A, 226B are located in the notches 231 A, 23 IB and are forced apart by a tapering inner surface on the lips 227A, 227B. When the top surface of the lips 227A, 227B pass over the bottom surface of the lower nut member 230, the resilient tabs snap back towards each other, locking the resilient flanges into the notches 231 A, 23 IB. In this way, the upper mounting support 220 may be clipped to the lower nut member 230, and the upper mounting support 220 and the lower nut member 230 may be loosely coupled to one another even in the absence of the fastener member 206.

[0089] The lower nut member 230 includes a central plate portion 233 which defines a protruding threaded hole 236 with internal threads configured to mate with the external threads of the threaded shank 212 of fastener member 206. Central plate portion 233 includes notches 231 A, 23 IB for receiving the flanges of retaining clips 226A, 226B. Opposing ends of lower nut member 230 also include upwardly-angled flanges 234A, 234B that engage elongated recesses of a rail. See, for example, elongated recesses 1027A and 1027B of rail 1010 shown in Fig. 15. The upwardly angled flanges 234A, 234B include piercing portions 232A, 232B that may be formed as a serrated edge. These piercing portions 232A, 232B are sufficiently hard and sharp so as to penetrate an inner surface layer of the recesses of a rail when the MLPE mounting assembly 200 is tightened on the rail, thereby electrically bonding the MLPE mounting assembly 200 to the rail.

[0090] As shown in Figs. 6A-6D, the support tabs 224A, 224B and / or the piercing portions 232A, 232B may include one or more rounded comers, which enable the upper mounting support 220 and / or the lower nut member 230 to be rotated (but not beyond 90°) so as to ease positioning and tightening of the MLPE mounting assembly 200 within the rail.

[0091] Additionally, referring again to Figs. 6A and 6B, the fastener member 206 may include a captured (or integrated) washer 210, with an underside of the washer 210 having a plurality of sharp ridges or raised portions formed thereon. These ridges on washer 210 allow for an improved coupling and electrical bonding between the item to be mounted (e.g., clamp 10) and the MLPE mounting assembly 200 when the MLPE mounting assembly 200 is sufficiently tightened.6742193.DOCX 12Attorney Docket No. 09549-2504162

[0092] Turning briefly to Fig. 6E, MLPE mounting assembly 200 is provided partially configured and fully configured, with a fastener 206 shown inserted in the fully configured version. Fig. 6E is provided to illustrate how MLPE mounting assembly 200 is assembled.

[0093] In a non-limiting aspect or embodiment, the upper mounting support 220 may be formed of a non-metallic material such as, e.g., plastic, while the lower nut member 230 may be formed of an electrically conducting material such as, e.g., aluminum, stainless steel, carbon steel, titanium, etc. However, in other embodiments, it is to be understood that one or both of upper mounting support 220 and lower nut member 230 may be formed of one or more different materials, including non-metallic materials, and upper mounting support 220 is not limited to non-metallic materials and may be formed of, e.g., aluminum, steel, titanium, etc.

[0094] Turning now to Figs. 7A-7G, various views and components of a wire clamp 310 according to one non-limiting embodiment of the present disclosure are shown. Figs. 7C1 and 7C2 show the clamp 310 as a single piece.

[0095] Wire clamp 310 is similar to the wire clamp 10 of Figs. 1-4 with a few differences. As shown, wire clamp 310 includes a bottom portion 312 and a top portion 314. The bottom portion 312 and top portion 314 form a slot 315 to receive a fastener 316. Any suitable fasteners may be used including any fastener assemblies described in this disclosure. Both the bottom portion 312 and the top portion 314 are generally rectangular and complementary in shape so that the portions 312, 314, when connected via the fastener 316, define channels 332A, 332B for routing and clamping wires W therethrough.

[0096] As shown, the left-hand side LH of wire clamp 310 is similar to the wire clamp 10 of Fig. 1. The right-hand side RH of wire clamp 310 differs though and does not include flanges, such as flanges 24B, 24D of wire clamp 10. Rather, right-hand side RH includes channel 332B that is fully enclosed and may not open to receive wires W. In other words, top portion 314 and bottom portion 312 of the right-hand side RH are continuous and integral with each other, defining a loop section 350. The loop section 350 may enclose the channel 332B. The loop section 350 may be a loop-like or cylindrical structure.

[0097] It should be appreciated that the geometry of wire clamp 310 is conducive to pressing the wire(s) W into the clamp 310, and the clamp 310 left-hand side LH wanting to open and accept the wires W into channel 332A. However, the geometry is such that once in the channel 332A, the clamp 310 limits the wires W from popping out until securement is complete.

[0098] Fig. 7A shows the clamp 310 on a rail R and Fig. 7B provides an exploded view of components used in Fig. 7A. In Fig. 7A, wire clamp 310 is adjustably attached to a rail R. Wire clamp 310 is shown engaged with rail R using fastener 316 and mounting hardware (not6742193.DOCX 13Attorney Docket No. 09549-2504162 visible), with the wire clamp 310 oriented perpendicular to the rail R. More discussion of how wire clamps engage with the rails will be discussed in later Figures.

[0099] Fig. 7B includes clamp 310, upper mounting support 370, a lower nut member 380, and a fastener member 316. Fig. 7D shows lower nut member 380 in more detail, and Fig. 7E shows upper mounting support 370 in more detail.

[0100] Turning to Figs. 7C1 and 7C2, the bottom portion 312 and top portion 314 include a bottom channel portion 320A and a top channel portion 320B, respectively. The bottom channel portion 320A and top channel portion 320B may be in communication with lips or flanges 324A and 324B, respectively. As shown, lip or flange 324A extends proximate to a sidewall 322A of bottom channel portion 320A and lip or flange 324B extends proximate to a sidewall 322B of top channel portion 320B. Lip or flange 324A is angled downward relative to the bottom portion 312 and lip or flange 324B is angled upward relative to the top portion 314. The lips or flanges 324A and 324B may be at a contoured angle and cooperate with each other. Additionally, the lips or flanges 324A and 324B form an angle of divergence X. Angle X is preferably an angle of divergence of between about 25-65 degrees.

[0101] Lips or flanges 324A and 324B may be resilient and separable to provide clearance for manual insertion of at least one wire W between the lips or flanges 324A and 324B and into wire channel 332A. The lips or flanges 324A and 324B may come into contact with each other after insertion of at least one Wire W. However, differing from Fig. 1, the lips or flanges 324A and 324B may be in a direction opposite the loop section 350.

[0102] Turning to Figs. 7D and 7E, upper mounting support 370 includes a central portion 373. A through-hole 376 is provided in the central portion 373 to allow a threaded shank of the fastener member 316 to pass therethrough. The upper mounting support 370 also includes a pair of deflectable, downwardly-extending clips 376A, 376B, wherein the clips 376A, 376B are configured to releasably engage with respective notches 381 A, 38 IB of the lower nut member 380. The clips 376A, 376B include downwardly extending resilient tabs or flanges, which flanges include inwardly extending lips 377A, 377B. As the upper mounting support 370 is pressed onto the lower nut member 380, the clips 376A, 376B are located in the notches 381 A, 38 IB and are forced apart by a tapering inner surface on the lips 377A, 377B. When the top surface of the lips 377A, 377B passes over the bottom surface of the lower nut member 380, the resilient tabs snap back towards each other, locking the resilient flanges into the notches 381 A, 38 IB. In this way, the upper mounting support 370 may be clipped to the lower nut member 380, and the upper mounting support 370 and the lower nut member 380 may be loosely coupled to one another even in the absence of the fastener member 316.6742193.DOCX 14Attorney Docket No. 09549-2504162

[0103] The lower nut member 380 includes a central plate portion 383 which defines a protruding threaded hole 386 with internal threads configured to mate with the external threads of the threaded shank of fastener member 316. Central plate portion 383 includes notches 381 A, 38 IB for receiving the flanges of retaining clips 376A, 376B. Opposing ends of lower nut member 380 also include upwardly-angled flanges 384A, 384B that engage elongated recesses of a rail. See, for example, elongated recesses 1027A and 1027B of rail 1010 shown in Fig. 15. The upwardly angled flanges 384A, 384B include piercing portions 382A, 382B that may be formed as a serrated edge. These piercing portions 382A, 382B are sufficiently hard and sharp so as to penetrate an inner surface layer of the recesses of a rail when the mounting assembly is tightened on the rail, thereby electrically bonding the mounting assembly to the rail.

[0104] Referring back to Fig. 7B, in some embodiments, one or more of the upper mounting support 370, a lower nut member 380, and a fastener member 316 may be replaced with a different mounting assembly. For example, the MLPE mounting assembly 200, shown in phantom and described in Fig. 6, may be used to secure clamp 310 to rail R.

[0105] Turning now to Figs. 7F and 7G, a cutaway view of the mount 310 in a rail R is shown. Upper mounting support 370 is shown suspending the nut and assembly and lower nut member 380 is shown engaged with rail R.

[0106] Turning now to Figs. 8A-8C, perspective views of a two-piece wire clamp 410 according to one non-limiting embodiment of the present disclosure are shown. Fig. 8A shows the clamp 410 as two pieces, Fig. 8B shows various views of a top portion 414 of clamp 410, and Fig. 8C shows various views of a bottom portion 412 of clamp 410.

[0107] Wire clamp 410 is similar to the wire clamp 10 of Figs. 1-4 with a few differences. As shown, wire clamp 410 includes a bottom portion 412 and a top portion 414. The bottom portion 412 and top portion 414 are joined together via a fastener (not shown). Any suitable fasteners may be used including any fastener assemblies described in this disclosure. Both the bottom portion 412 and the top portion 414 are generally rectangular and complementary in shape so that the portions 412, 414, when connected via the fastener, define channels 432A, 432B for routing and clamping wires W therethrough.

[0108] As shown, the bottom portion 412 and top portion 414 are two separate pieces. This is a departure from the wire clamp 10, where center portion 40 includes a knuckle 48 that is integral to both top body portion 44 and bottom body portion 42 and connects these portions so that wire clamp 10 is a single part. However, operation of the wire clamp 410 is nonetheless6742193.DOCX 15Attorney Docket No. 09549-2504162 similar to wire clamp 10. Placement of wire clamp 410 onto various rails will be provided in later Figures.

[0109] Turning now to Figs. 9A and 9B, top and bottom perspective views of a wire clamp 510 according to one non-limiting embodiment of the present disclosure are shown. Wire clamp 510 includes a bottom portion 512 and a top portion 514. The bottom portion 512 and top portion 514 are joined together via a screw 516. While a screw 516 is shown, other fastening means known to those having skill in the art may be used. Both the bottom portion 512 and the top portion 514 are generally rectangular and complementary in shape so that the portions 512, 514, when connected via the screw 516, define channels 532A, 532B for routing and clamping wires W therethrough. It is understood that the bottom portion 512 and the top portion 514 may take other shapes, so long as they fit together to define a channel or channels 532A, 532B for the wires W.

[0110] With reference to Fig. 9D, the bottom portion 512 will now be described. The bottom portion 512 includes a first base 520. The first base 520 is divided into a first side 520A and a second side 520B, which are separated by a barrier 522. As shown, the barrier 522 is partially elliptical, having two sidewalls 522A, 522B curving about an aperture 524. The sidewalls 522A, 522B define a shape that is similar to that of a football. Such a shape allows a user to maximize the bend radius of the wires that run through the clamp 510. The first sidewall 522A extends along and serves as a demarcation line of the first side 520A. The second sidewall 522B extends along and serves as a demarcation line of the second side 520B. The sidewalls 522A, 522B are curved to prevent the wires W from being pinched together when the top portion 514 is connected to the bottom portion 512. The curved sidewalls 522A, 522B also cause the wires W to curve when placed in the bottom portion 512, which may allow for more efficient and organized routing of the wires W in the system to which the wire clamp 510 is applied. The curvature also prevents pinching or unnecessary bunching of the wires W, which can lead to entanglements. While shown as an elliptical or football-like shape, the sidewalls 522A, 522B may take different rounded shapes, such as an ovular or circular shape, in order to properly orient the wires W within the wire clamp 510.

[0111] Located centrally relative to the two sidewalls 522A, 522B of the barrier 522 is the aperture 524 that receives the screw 516 therein. The aperture 524 may have threads (not shown) that correspond to threads on the screw (not shown) to facilitate the connection therebetween. The space between the sidewalls 522A, 522B and around the aperture 524 may be smooth and includes two posts 526A, 526b extending upward from the first base 520. The posts 526A, 526B are received within corresponding holes or cutouts 546A, 546B in the top6742193.DOCX 16Attorney Docket No. 09549-2504162 portion 514. The posts 526A, 526B serve to help orient the bottom portion 512 and the top portion 514 during their connection. The posts 526A, 526B also add additional points of engagement between the bottom portion 512 and the top portion 514, which help ensure the portions 512, 514 remain together and in the correct relative orientation when in use.

[0112] The bottom portion 512 also includes legs 528A, 528B extending proximate the comers of the first base 520. The legs 528A, 528B extend outward from the comers, with each leg 528 A, 528B extending in opposite directions. The legs 528 A, 528B are generally wedge shaped and include sloped outer surfaces 530A, 530B. The slopes of these surfaces 530A, 530B extend in the same direction as the legs 528A, 528B extend away from the first base 520. While the sidewalls 522A, 522B demarcate one side of the first base’s 520 sides 520A, 520B, the legs 528A, 528B demarcate the opposing side. In particular, leg 528A opposes sidewall 522A, and leg 528B opposes sidewall 522B. The opposing nature of these elements at least partially defines wire channels 532A, 532B, with sidewall 522A and leg 528A defining a first wire channel 532A therebetween and sidewall 522B and leg 528B defining a second wire channel 532B therebetween. The sloped nature of the legs 528A, 528B ensures that the portions of the legs 528A, 528B facing their respective sidewalls 522A, 522B are high enough to retain the wires W in their respective channels 532A, 532B. As a result of these features, the shapes of the legs 528A, 528B can be anything that is large enough to retain the wires W in the channels 532A, 532B. Within the channels 532A, 532B, the sides 520A, 520B include ridges 534 (not all labeled for clarity). The ridges 534 provide a cormgated surface on the sides 520A, 520B that can help align the wires W within the channels 532A, 532B. The corrugation of the ridges 534 also creates some friction that helps retain the wires W in their specific location within the channels 532A, 532B.

[0113] In some non-limiting aspect or embodiments, a mounting support or base 570 may be used with wire clamp 510. Mounting support or base 570 includes a central portion 573. A through-hole 576 is provided in the central portion 573 to allow a threaded shank of the fastener member or screw 516 to pass therethrough. The mounting support or base 570 also includes a pair of deflectable, downwardly-extending clips 577A, 577B. While not explicitly shown, the downwardly-extending clips 577A, 577B may engage any suitable lower nut member 230, 380, shown and described above. The through-hole 576 may be aligned with the aperture 524, allowing insertion of fastener or screw 516 into through-hole 576 through the aperture 524 to engage with the nut and couple the mounting supporting base 570 and the clamp 510 to the rail Rl.6742193.DOCX 17Attorney Docket No. 09549-2504162

[0114] The central portion 573 may also include positioning tabs 580 that engage or interact with the bottom surface 590 of the bottom clamp portion 512. The positioning tabs 580 may fit into recesses 592 or between arms 594 of bottom surface 590. In some non-limiting aspects or embodiments, the positioning tabs 580 position the wire clamp 510 in 45 degree rotational increments, thereby allowing “clocking” of the wire clamp 510 relative to the rail R.

[0115] Referring to Fig. 9C, in some non-limiting aspects or embodiments, the top portion 514 also includes a base 540 with a first side 540A and a second side 540B. The sides 540A, 540B are divided by a central portion 540C that includes a protrusion 542 extending therefrom. As the protrusion 542 extends in the direction of the bottom portion 512, it defines a cavity 543 in the top surface 519 of the top portion 514. The protrusion 542 is rounded and shaped so as to at least partially complement the curved sidewalls 522A, 522B of the bottom portion 512. The protrusion 542 includes an aperture 554 and holes or cutouts 546A, 546B that respectively align with aperture 554 and posts 526A, 526B of the bottom portion 512. The aperture 554 may include threads (not shown) that correspond to threads on the screw (not shown) and, along with the alignment of the holes 546A, 546B and posts 526A, 526B, serve to orient and connect the top portion 514 to the bottom portion 512. Based on these alignments, the protrusion 542 is shaped to fit within the space defined within the curved sidewalls 522A, 522B. As shown, the protrusion 542 is rounded, having one circle extending downward, defining the aperture 554. It is understood that different shapes can be used, so long as the protrusion 542 allows for the alignments discussed herein. It is also to be understood that the arrangement of the features associated with the protrusion 542 and the features associated with the partially elliptical barrier 522 can be reversed. In this instance, the top portion 514 may include the curved sidewalls 522A, 522B and posts 526A, 526B, and the bottom portion 512 may include the protrusion 542 and holes 546A, 546B.

[0116] The top portion 514 also includes flanges 548A, 548B extending proximate the comers of the second base 540. The flanges 548A, 548B correspond with and are aligned over the legs 528A, 528B of the bottom portion 512 when the wire clamp 510 is assembled. The flanges 548A, 548B are angled both downward and upward relative to the second base 540. This means that the flanges 548A, 548B include downward extending portions 550A, 550B, that, when the wire clamp 510 is assembled, contact at least a portion of the sloped outer surfaces 530A, 530B, of the legs 528A, 528B. Extending from the downward extending portions 550A, 550B are upward extending portions 552A, 552B, extending away from the sloped outer surfaces 530A, 530B, of the legs 528A, 528B. The upward extending portions6742193.DOCX 18Attorney Docket No. 09549-2504162552A, 552B provide areas of the top portion 514 that can be easily gripped to remove the top portion 514 from the bottom portion 512.

[0117] The lower surface of upwardly extending portions 552A, 552B slope upward and away from the sloped outer surfaces 530A, 530B, of the legs 528A, 528B of the bottom portion 512. Thus, the sloping surfaces of the upper and lower pieces extend outward and away from each other, such that they may touch or almost touch at the portions of the wire clamp 510 where the legs 528A, 528B define the outermost border of the wire channels 532A and 532B. As shown in Fig. 9A, the legs 528A, 528B and the flanges 548A, 548B diverge to create a mouth or clearance 549.

[0118] In some non-limiting aspects or embodiments, the mouth or opening may be defined as forming an angle of divergence of between about 25-65 degrees. This mouth or opening can assist in guiding wires W into the channels 532A, 532B and in separating the bottom portion 512 and the top portion 514 to allow the wires W to enter into the channels 532A, 532B.

[0119] In some non-limiting aspects or embodiments, the sides 540A, 540B of the top portion 514 also serve as channel walls 554A, 554B. The channel walls 554A, 554B further define the wire channels 532A, 532B along with the sidewalls 522A, 522B and legs 528A, 528B, of the bottom portion 512. The channel walls 554A, 554B may contact the tops of the wires W upon the assembly of the wire clamp 510, or the sizing of the top portion 514 and the bottom portion 512 may be such that a small space may be provided between the channel walls 554A, 554B and the wires W when the clamp 510 is assembled. The channel walls 554A, 554B may also include ridges 534 to provide similar corrugation benefits as the ridges 534 of the bottom portion 512. The shape and sizing of both sets of ridges 534 allows for a variety of wires W to be gripped and secured within the wire channels 532A, 532B. The arrangement shown also allows for wires W of different sizes to be received and secured within the wire channels 532A, 532B. Finally, the top portion 514 is arched over the bottom portion 512, having a curved sidewall 558 that arches over the first base 520 of the bottom portion 512. This shape allows for the wires W to fit snugly and safely within the channels 532A, 532B when the top portion 514 is mated with and connected to the bottom portion 512.

[0120] In some non-limiting aspects or embodiments, a method of assembly is that the top portion 514 and the bottom portion 512 can be assembled loosely with the posts 526A, 526B extending into the holes 546A, 546B and the protrusion 542 extending between the sidewalls 522A, 522B. The wires W can be inserted into channels 532A, 532B. The screw 516 can be inserted through aperture 524, 554, then the assembly can be placed on an installation surface,6742193.DOCX 19Attorney Docket No. 09549-2504162 such as a rail top surface, and the screw 516 can be driven into the installation surface until the entire wire clamp 510 assembly is tightened and fixed onto the installation surface.

[0121] The orientation of the top portion 514 and the bottom portion 512 relative to each other is fixed by the interlocking relationship of the posts 526A, 526B and the holes 546A, 456B as well as the interlocking relationship between the protrusion 542 and the recessed area between the sidewalls 522A, 522B. The assembled wire clamp 510 allows for the top and bottom portions 514, 512 to freely rotate around the screw 516. The wire clamp 510 can be installed in any orientation on an installation surface. For instance, the wire clamp 510 can be installed on top of a rail R such that the wires extend perpendicular to the longitudinal axis of the rail, parallel to the longitudinal axis of the rail or at any angle in between. This provides maximum flexibility to an installer who is running wires in a solar array and must get the wires across a distance on a roof or other installation environment while preventing the wires from sagging and touching the roof or other surface.

[0122] The apertures 524, 554 may be clearance holes without including threads. The wire clamp 510 can be assembled and installed on an installation surface without fully tightening the screw 516. Then, the wires W can be inserted through the mouth or opening between the upward extending portions 552A, 552B of the top portion 514 and the legs 528A, 528B of the bottom portion 512. In such an arrangement, one of the flanges 548A, 548B located at one end of the top portion 514 can be pulled upward to create a space between the respective flanges 548 A, 548B, and their corresponding legs 528 A, 528B so that a wire W can fit between that space to be placed in the desired wire channel 532A, 532B.

[0123] Turning briefly to Fig. 9E, wire clamp 510 is shown engaged on rail Rl, with the wire clamp 510 at an angle from rail Rl . For example, as shown, wire clamp 510 is rotationally oriented to hold wires W at a position 45 degrees from the rail R, by being clocked by positioning tabs 580. While not explicitly shown, the engagement of wire clamp 510 is similar to other clamps described herein, with a lower nut member 230 or other suitable mount assembly component(s) engaging elongated recesses of the rail Rl. For differing rails, such as R2, the head of a fastener may be inserted into a groove to secure the wire clamp 510 to the rail. Examples with differing rails are described further in Figs. 12 and 14.

[0124] As shown in Figs. 10A-10D, the wire clamp 10 can be applied to a rail R used in an industrial environment, such as a solar panel array. To apply the wire clamp 10 to the rail R, or to whatever element the wire clamp 10 is being applied, the rail R may include an aperture to receive the fastener 206 therein.6742193.DOCX 20Attorney Docket No. 09549-2504162

[0125] Fig. 10A shows the wire clamp 10 rotationally oriented to hold the wires W perpendicularly to the rail R. Fig. 10B shows an exploded view of the wire clamp 10 along with an upper mounting support 220 and a lower nut member 230. Fig. 10C shows the wire clamp 10 sitting on top of rail R, and Fig. 10D shows the cross section of the wire clamp 10 in a cross-sectional view when engaged with the rail R.

[0126] It should be appreciated that a variety of different types of rails may be used with the present wire clamps. For reference, a more detailed version of a rail type 1010 is provided in Fig. 15.

[0127] To apply the wire clamp 10 to the rail R, the wires W can be placed within the wire channels 32A, 32B of the wire clamp 10. The wire clamp 10 thereafter will be seated in between the upper mounting support 220 and fastener 206 and lower nut member 230 will receive the fastener 206 and serve to tighten the clamp 10. The lower nut member 230 may engage one or more elongated recesses 1027A, 1027B of rail R.

[0128] In other embodiments, the wires W can be placed within the wire channels 32A, 32B, and the top portion 14 can be applied to the bottom portion 12 after the wire clamp 10 is placed on top of the rail Rl. The order of steps may be changed as desired.

[0129] Additionally, while mounting components 220, 230 have been shown as used, any suitable mounting assembly or partial mounting assembly may be used to secure wire clamp 10 to rail Rl.

[0130] Turning briefly to Figs. 11A and 1 IB, wire clamp 10 is shown rotationally oriented to hold the wires W at different angles compared to the rail Rl. In Fig. 11A, wire clamp 10 is shown rotationally oriented to hold the wires W at an angle from rail Rl, and in Fig. 1 IB, wire clamp 10 is shown rotationally oriented to hold the wires W parallel to rail Rl. It should be appreciated that although the wire clamp 10 is in a different direction or angle from rail Rl, the mounting assembly or mechanism remains the same within the rail Rl.

[0131] Turning now to Figs. 12A-12C, various views of a wire clamp 10 according to one non-limiting embodiment of the present disclosure mounted to a rail R2 are shown. As shown, Figs. 12A-12C include wire clamp 10 being mounted to a different type of rail R2. Consequently, the mounting hardware may differ than described with previous Figures.

[0132] Turning to Fig. 12C1, it is clear that fastener assembly 110 is received upside down in a groove of the rail R2. Fig. 12C2 shows a close up of Fig. 12C1, where the head 114 of the fastener assembly 110 slides along a groove(s) within R2, in a similar fashion to the elongated grooves of rail Rl, shown in Fig. 15.6742193.DOCX 21Attorney Docket No. 09549-2504162

[0133] As described in Fig. 5B, the fastener assembly 110 may include a resistance patch region 166A on the threaded shank 116, which may serve to operate as a positioning mechanism so that rotation of the nut to tighten the fastener assembly 110 onto the rail R rotates the head 114 of the fastener member 104 into the proper orientation for engagement with the rail R. In some non-limiting aspects or embodiments, the head 114 is shaped like a square or rectangle 164. The fastener assembly 110 may be inserted such that the head 114 is upside down and the nut member 120 is placed on the threaded shank 116 above the clamp 10.

[0134] Continuing discussion of Figs 12A to 12C, as described with reference to Fig. 10, to apply the wire clamp 10 to the rail R2, the wires W can be placed within the wire channels 32A, 32B of the wire clamp 10. The wire clamp 10 thereafter will be seated in between the nut member 120 and a top surface of rail R2, fastener assembly 110 will serve to tighten the clamp 10 to the rail R2. The head 114 of the screw may engage one or more elongated recesses of rail R2.

[0135] In other embodiments, the wires W can be placed within the wire channels 32A, 32B, and the top portion 14 can be applied to the bottom portion 12 after the wire clamp 10 is placed on top of the rail R2. The order of steps may be changed as desired. In some embodiments, additional mounting components may be used in mounting wire clamp 10 to the rail R2.

[0136] Turning now to Figs. 13A-13D, various views of a wire clamp 410 according to one non-limiting embodiment of the present disclosure mounted to a rail are shown. Fig. 13A shows a two-piece clamp 410 mounted to a rail Rl. Fig. 13B shows an exploded view of the wire clamp 410 along with an upper mounting support 370 and a lower nut member 380. Fig. 13C shows the wire clamp 410 sitting on top of rail Rl and Fig. 13D shows the cross section of the wire clamp 410 in a cross-sectional view when engaged with the rail Rl. The mounting of wire clamp 410 to rail Rl is similar to the mounting of wire clamp 10 to rail Rl, discussed in Figs. 10A-10D, so will not be repeated here.

[0137] Turning now to Figs. 14A and 14B, various views of a wire clamp 410 according to one non-limiting embodiment of the present disclosure mounted to a rail are shown. Fig. 14A shows the wire clamp 410 sitting on top of rail R2, Fig. 14B1 shows the cross section of the wire clamp 410 in a cross-sectional view when engaged with the rail R2, and Fig. 14B2 shows a close up of Fig. 14B1. The mounting of wire clamp 410 to rail R2 is similar to the mounting of wire clamp 10 to rail R2, discussed in Figs. 12A-12C, so will not be repeated here.

[0138] Referring to Figs. 15A and 15B, a rail 1010 in accordance with an aspect of the present disclosure is illustrated. Rail 1010 is configured to secure one or more solar panels6742193.DOCX 22Attorney Docket No. 09549-2504162(not shown) to a support surface such as, e.g., a mounting bracket affixed to a rooftop. In certain embodiments, the rail 1010 comprises an electrically conductive material that may be used to connect and electrically bond the components of the mounting system. For example, in one embodiment, the rail 1010 may be formed of extruded aluminum. Furthermore, the rail 1010 may have, e.g., a mill finish, an anodized finish, a painted finish, etc. However, it is to be understood that rail 1010 may be formed of any appropriate electrically conductive metallic material such as, e.g., stainless steel, carbon steel, titanium, etc. Additionally and / or alternatively, the rail 1010 may be formed by another appropriate manufacturing method such as, e.g., roll forming, forging, casting, milling, roll forming, stamping, etc. The length and / or overall dimensions of rail 1010 may vary dependent upon the specific application of the railbased mounting system.

[0139] Rail 1010 includes a pair of opposing sidewalls 1011, outer sidewall surfaces 1012, inner sidewall surfaces 1014, and a bottom surface 1018. A top opening 1020 is formed in the upper portion of the rail 1010, thereby resulting in rail 1010 being substantially U-shaped and having an open channel formed therein. The top opening 1020 is longitudinal, extending the length of the rail 1010. As will be discussed in further detail below, such an open channel formation enables various clamp assemblies and other components of the mounting system to be retained within the rail 1010.

[0140] An intermediate lateral wall 1015 extends between the inner sidewall surfaces 1014 of the sidewalls 1011 and longitudinally along the length of the rail 1010, thereby providing additional structural support to the respective sidewalls 1011 of the rail 1010, as well as providing an intermediate top surface 1016 forming a bottom to the open channel formed by top opening 1020 and the two sidewalls 1011. As will be described below, the intermediate top surface 1016 may also provide a support surface for one or more rail splices, which are configured to allow multiple rails to be linearly coupled together in an end-to-end fashion as needed during installation. Furthermore, a rib 1023 may extend from the intermediate top surface 1016, with the rib 1023 also extending longitudinally along the length of rail 1010. Rib 1023 may provide structural support to the intermediate top surface 1016.

[0141] While rib 1023 extends upwardly from intermediate top surface 1016 in Figs. 15A and 15B, it is to be understood that rib 1023 could extend downwardly from intermediate lateral wall 1015. Furthermore, while only one rib 1023 is shown, it is to be understood that a plurality of ribs 1023 may be present. Additionally and / or alternatively, one or more ribs 1023 may extend from the inner sidewall surface 1014.6742193.DOCX 23Attorney Docket No. 09549-2504162

[0142] Referring still to Figs. 15A and 15B, a first conduit 1021 is formed along the longitudinal length of rail 1010, with first conduit 1021 defined by the intermediate lateral wall 1015, the bottom wall 1018, and the tapered side wall portions 1013. The first conduit 1021 may be sized and configured to allow electrical wires (not shown) associated with the solar panel installation to be fed therethrough. In this way, the first conduit 1021 may both protect, conceal, and direct at least some of the electrical wires and connectors utilized in the solar panel installation.

[0143] Similarly, rail 1010 may further include a second, trough-like conduit 1022 formed by the sidewalls 1011 and the intermediate lateral wall 1015. Unlike first conduit 1021, second conduit 1022 is configured as an open channel due to top opening 1020. Second conduit 1022 may also be sized and configured to allow electrical wires associated with the solar panel installation to be fed therethrough. The top opening 1020 allows the wires to be placed into the second conduit 1022 from above at any point along the rail 1010.

[0144] Proximate to the bottom surface 1018, the tapered sidewall portions 1013 of rail 1010 further include a pair of opposing channels 1024A, 1024B. The channels 1024A, 1024B extend longitudinally along the rail 1010 such that each channel 1024 A, 1024B forms a concave recess formed substantially flush with the tapered sidewall portions 1013 to provide a secure mounting track for receipt of corresponding surfaces of a rail attachment bracket, which clamp onto the channels 1024A, 1024B so as to secure the rail 1010 to, e.g., an appropriate mounting bracket, as will be described further hereinbelow. As shown in Figs. 15A and 15B, the channels 1024A, 1024B are located along angled surfaces of the tapered sidewall portions 1013, wherein the tapered sidewall portions 1013 angle inwardly from approximately the intermediate top surface 1016 to the bottom surface 1018. However, in other embodiments, it is to be understood that rail 1010 could be configured such that there is no such inward (i.e., V-shaped) taper between the intermediate surface 1016 to the bottom surface 1018.

[0145] Rail 1010 further includes a pair of upper top surfaces 1029 A and 1029B. The upper top surfaces 1029 A, 1029B serve as a support surface for solar panel frames and related accessories and components. Rail 1010 further includes projections 1025A, 1025B positioned in proximity to respective upper top surfaces 1029A, 1029B. The projections 1025A, 1025B extend linearly along the length of rail 1010 and are each partially inwardly and downwardly directed so as to form an angled interface within the rail 1010. Furthermore, below projections 1025A, 1025B, a pair of substantially hook-shaped protrusions 1026A, 1026B extend inward from opposing sides of inner sidewall surfacel014. As will be described in further detail6742193.DOCX 24Attorney Docket No. 09549-2504162 below, the protrusions 1026A, 1026B are sized and configured so as to partially retain a portion of a rail splice used to couple two separate rails 1010 during the installation process.

[0146] Between the projections 1025A, 1025B and the protrusions 1026A, 1026B, a pair of elongated recesses 1027A, 1027B are formed along the length of rail 1010. As will be described further herein, these recesses 1027 A, 1027B are configured to accommodate a nut portion of various clamp assemblies used to couple solar panels and / or related componentry to the rail 1010. Above the projections 1025A, 1025B, a pair of respective top ledge surfaces 1028A, 1028B extend linearly along the length of rail 1010. While the recesses 1027A, 1027B (and the angled projections 1025A, 1025B) may accommodate the nut portion of the clamp assemblies, the ledge surfaces 1028A, 1028B and / or upper top surfaces 1029A, 1029B of the rail 1010 may provide a support surface for an upper portion of the clamp assemblies. In this way, when a clamp assembly is tightened, the upper grip portion rests upon the ledge surfaces 1028 A, 1028B and / or upper top surfaces 1029 A, 1029B, while the nut portion of the clamp assembly is drawn upward within the recesses 1027A, 1027B toward the projections 1025A, 1025B, eventually securing the clamp assembly to the rail 1010. Additionally, this configuration of the rail 1010 also allows for the coupling of numerous other accessories and features aside from the clamp assembly, such as, e.g., a module-level power electronics (MLPE) mounting assembly, an accessory clamp, a grounding wire clamp, a grounding lug, etc.

[0147] Referring to Fig. 16, a method of clamping wires in a solar panel system is illustrated. A wire clamp is secured to a rail. The rail may support one or more solar panels. The wire clamp includes a top portion and a bottom portion defining a wire channel, and opposed flanges that are adjacent to the wire channel. At least one wire is placed into contact with the opposed flanges. The at least one wire has a longitudinal axis that may be approximately normal to a longitudinal axis of the wire clamp. The wire may be pressed to separate the opposed flanges to provide a clearance between the flanges, and the wire may be further pressed through the clearance and into the wire channel.

[0148] While various aspects of the wire clamps were provided in the foregoing description, those skilled in the art may make modifications and alterations to these aspects without departing from the scope and spirit of the invention. For example, it is to be understood that this disclosure contemplates that, to the extent possible, one or more features of any aspect can be combined with one or more features of any other aspect. Accordingly, the foregoing description is intended to be illustrative rather than restrictive. The invention described6742193.DOCX 25Attorney Docket No. 09549-2504162 hereinabove is defined by the appended claims, and all changes to the invention that fall within the meaning and the range of equivalency of the claims are to be embraced within their scope.6742193.DOCX 26

Claims

Attorney Docket No. 09549-2504162THE INVENTION CLAIMED IS:

1. A wire clamp comprising: a bottom portion comprising: a first bottom channel portion and a second bottom channel portion, a top portion comprising: a first top channel portion and a second top channel portion, the first and second top channel portions configured to cooperate with the first and second bottom channel portions, respectively, to form a first wire channel and a second wire channel; and a center portion comprising an aperture configured to receive a fastener for securing the wire clamp to a structure.

2. The wire clamp of claim 1, wherein the center portion further comprises a knuckle that is integral to and connects the bottom and top portions, thereby forming a single part.

3. The wire clamp of claim 1, wherein the first bottom channel portion and second bottom channel portion include at least one or more bottom flanges extending from first and second bottom channel portions.

4. The wire clamp of claim 3, wherein the first top channel portion and second top channel portion include at least one or more top flanges extending from first and second top channel portions.

5. The wire clamp of claim 4, wherein the bottom flanges and top flanges extend away from the bottom portion and top portion, respectively, and form an angle of divergence of between about 25-65 degrees.

6. The wire clamp of claim 1, wherein the bottom portion includes one or more ridges in the first and second bottom channel portions for gripping the one or more wires.6742193.DOCX 27Attorney Docket No. 09549-25041627. The wire clamp of claim 6, wherein the top portion includes one or more ridges in the first and second top channel portions for gripping the one or more wires.

8. The wire clamp of claim 7, wherein the ridges in the bottom portion and ridges in the top portion are staggered from each other so they do not grip the wire at the same location.

9. The wire clamp of claim 1, wherein the one or more wires comprise one or more of photovoltaic (PV) wires, homeruns, trunk cables, or other electrical wires.

10. The wire clamp of claim 1, wherein the first and second wire channels are the same size.

11. The wire clamp of claim 1, wherein the first and second wire channels are different sizes.

12. The wire clamp of claim 1, wherein the aperture of the center portion comprises a first aperture formed in the bottom portion and a second aperture formed in the top portion.

13. The wire clamp of claim 12, wherein the bottom portion comprises an at least partially elliptical first barrier extending from the first bottom channel portion around the first aperture and an at least partially elliptical second barrier extending from the second bottom channel portion around the second aperture.

14. The wire clamp of claim 12, wherein the top portion comprises a third and fourth aperture, wherein the bottom portion further comprises a first post and a second post extending from the bottom portion, and wherein the first post and the second post are configured to be received within the third aperture and the fourth aperture.

15. The wire clamp of claim 14, wherein the first post and the second post are disposed symmetrically about the first aperture.6742193.DOCX 28Attorney Docket No. 09549-250416216. The wire clamp of claim 1, wherein the top portion is at least partially arched about the bottom portion.

17. The wire clamp of claim 1, wherein the fastener comprises a t-nut, a cap screw, a t-bolt, a square bolt, or a portion of a fastener assembly, or any combination thereof.

18. The wire clamp of claim 1, wherein the structure is a rail.

19. The wire clamp of claim 18, wherein the wire clamp is configured to be parallel to, perpendicular to, or at an angle relative to the rail.

20. The wire clamp of claim 18, wherein the wire clamp is configured to sit on top of or partially within an open channel on top of the rail.

21. A wire clamp comprising: a bottom portion comprising a bottom channel portion, a planar bottom center portion and an opening in said bottom center portion; a top portion comprising a contoured top channel portion, a planar top center portion and an opening in said center portion which corresponds to the opening in said bottom center portion; a loop section connected to said bottom center portion and said top center portion; said bottom channel portion and said top channel portion cooperating to define a wire channel; each of said bottom portion and said top portion having a contoured flange, said contoured flanges opposing one another and having lips which diverge in a direction opposite said loop section; said contoured flanges being resilient and separable to provide a clearance for manual insertion of at least one wire between said lips and into said wire channel.

22. The wire clamp of claim 21, wherein said openings in said center portions define a slot for receiving a fastener.

23. The wire clamp of claim 22, wherein the slot is open-ended.6742193.DOCX 29Attorney Docket No. 09549-250416224. The wire clamp of claim 21, wherein the opposed contoured flanges are configured to resiliently come into contact with one another after insertion of the at least one wire.

25. The wire clamp of claim 21, wherein the bottom channel portion is planar.

26. The wire clamp of claim 21, wherein the clamp is of integral construction and is made from a resilient material.

27. The wire clamp of claim 26, wherein the material is sheet metal.

28. A wire routing system comprising: a rail with a longitudinal top opening; a coupling engageable with said top opening; and a wire clamp comprising: a bottom portion comprising: at least one bottom channel portion configured to receive one or more wires; a top portion comprising: at least one top channel portion configured to mate with a corresponding one of said at least one bottom channel portion to form at least one wire channel; and a body portion comprising an aperture configured to receive and align a fastener therethrough, thereby mounting the wire clamp and the coupling to the rail.

29. A method of clamping wires in a solar panel system comprising the steps of: securing a wire clamp to a rail, which rail is supporting one or more solar panels; said wire clamp having a top portion and a bottom portion defining a wire channel, and opposed flanges adjacent the wire channel;6742193.DOCX 30Attorney Docket No. 09549-2504162 placing at least one wire into contact with the opposed flanges with a longitudinal axis of said wire being approximately normal to a longitudinal axis of said wire clamp; pressing the wire to separate the flanges and provide a clearance between the flanges; and further pressing the wires through the clearance and into the wire channel.6742193.DOCX 31

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