Spring clip for mounting assembly

Abstract

A spring clip for a mounting assembly of a solar panel includes a base, a pair of arms, and a pair of protrusions. The pair of arms extends from the base. Each of the arms is independently pivotable with respect to the base. Each of the arms includes an outer arm surface. The pair of protrusions is on the pair of arms, respectively. Each of the protrusions includes a first protrusion surface. A first angle between the first protrusion surface and the outer arm surface is oblique.

Description

Attorney Docket No. 0275-001791 -WO-POASPRING CLIP FOR MOUNTING ASSEMBLYCROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims the benefit of U.S. Provisional Application No. 63 / 700,320, filed on September 27, 2024. The entire disclosure of the above application is incorporated herein by reference.FIELD

[0002] The present disclosure relates to a spring clip for a mounting assembly, such as a solar panel mounting assembly.BACKGROUND

[0003] This section provides background information related to the present disclosure which is not necessarily prior art.

[0004] Solar panels are coupled to support structures using mounting assemblies. Such mounting assemblies may include a panel bracket coupled to the solar panel and a carrier bracket coupled to the support structure. Support structures may include a rotatable horizontal support operatively coupled to a motor to pivot the solar panel, such as to track a position of the sun.

[0005] During installation, the solar panel having the panel bracket coupled thereto is moved to a location of the support structure and carrier bracket by operators. The operators couple the panel bracket to the carrier bracket by aligning respective apertures of the panel and carrier brackets and then inserting a discrete fastener, such as a wedge, into the apertures using a tool, such as a rubber mallet. The process is repeated for a plurality of aligned apertures.

[0006] The installation process is time-consuming and requires multiple operators, precision alignment, and discrete components and tools. Thus, a need exists for a mounting assembly that can be quickly installed while reducing additional components, discrete tools, and operator time.SUMMARY

[0007] This section provides a general summary of the disclosure, and is not a comprehensive disclosure of its full scope or all of its features.Attorney Docket No. 0275-001791 -WO-POA

[0008] An example of a spring clip for a mounting assembly of a solar panel includes a base, a pair of arms, and a pair of protrusions. The pair of arms extends from the base. Each of the arms is independently pivotable with respect to the base. Each of the arms includes an outer arm surface. The pair of protrusions is on the pair of arms, respectively. Each of the protrusions includes a first protrusion surface. A first angle between the first protrusion surface and the outer arm surface is oblique.

[0009] In one aspect, the first angle ranges from 5° to 45°.

[0010] In one aspect, the first angle ranges from 15° to 35°.

[0011] In one aspect, each of the pair of protrusions further includes a second protrusion surface. A second angle between the second protrusion surface and the outer arm surface is oblique.

[0012] In one aspect, the second angle ranges from 15° to 55°.

[0013] In one aspect, each of the protrusions further includes a third protrusion surface and a fourth protrusion surface. The third protrusion surface is between the outer arm surface and the second protrusion surface. The fourth protrusion surface is between the outer arm surface and the first protrusion surface.

[0014] In one aspect, the third protrusion surface is perpendicular to the outer arm surface. The fourth protrusion surface is perpendicular to the outer arm surface.

[0015] In one aspect, each of the pair of arms includes a first portion and a second portion. The first portion is between the second portion and the base. The first portion is convex.

[0016] In one aspect, the second portion is concave.

[0017] In one aspect, the first portion includes a first inner diameter surface. The first inner diameter surface defines a first radius of curvature. The second portion includes a second inner diameter surface. The second inner diameter surface defines a second radius of curvature. The first radius of curvature is less than the second radius of curvature.

[0018] In one aspect, each of the arms further includes a third portion. The second portion is between the first portion and the third portion.

[0019] In one aspect, the third portion is planar. The third portion includes a portion of the outer arm surface that forms the first angle with the first protrusion surface.

[0020] In one aspect, the spring clip is a single-piece, unitary structure.

[0021] In one aspect, the spring clip has a thickness of greater than or equal to 0.9 mm.

[0022] In one aspect, the thickness is uniform.Attorney Docket No. 0275-001791 -WO-POA

[0023] An example of a mounting assembly for a solar panel includes a bracket and a spring clip. The bracket is configured to be fixed to a solar panel. The bracket includes a wall. The wall at least partially defines an interior region. The wall defines a pair of apertures. The spring clip is at least partially in the interior region of the bracket. The spring clip includes a base and a pair of arms extending from the base. Each of the arms includes a protrusion. Each of the arms is pivotable with respect to the base. The spring clip is movable between a relaxed position and a flexed position. In the relaxed position, the pair of protrusions are at least partially in the pair of apertures, respectively. In the flexed position, the protrusions are outside of the apertures.

[0024] In one aspect, each of the protrusions is configured to engage a surface of a respective one of the apertures to prevent movement of the spring clip with respect to the bracket.

[0025] In one aspect, the interior region defines a transverse dimension. The base of the spring clip extends across greater than or equal to about 90% of the transverse dimension.

[0026] In one aspect, the base of the spring clip is directly engaged to a wall of the bracket.

[0027] An example of a method of assembling a solar panel to a structure includes aligning a protrusion of a mounting assembly with a receptacle of a carrier bracket along a first axis. The mounting assembly includes a bracket and a spring clip. The bracket defines an aperture. The spring clip includes a pivotable arm and the protrusion. The protrusion extends through the aperture. The method further includes translating the mounting assembly with respect to the carrier bracket along a second axis perpendicular to the first axis such that the protrusion engages a surface of the carrier bracket to move the spring clip from a relaxed position to a flexed position. The method further includes aligning the protrusion with the receptacle along the second axis such that the spring clip moves from the flexed position to the relaxed position and the protrusion extends at least partially into the receptacle.

[0028] Further areas of applicability will become apparent from the description provided herein. The description and specific examples in this summary are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure.Attorney Docket No. 0275-001791 -WO-POADRAWINGS

[0029] The drawings described herein are for illustrative purposes only of selected embodiments and not all possible implementations, and are not intended to limit the scope of the present disclosure.

[0030] FIG. 1 is a perspective view of an example of a solar panel assembly;

[0031] FIG. 2 is a partial perspective view of the solar panel assembly of FIG. 1 ;

[0032] FIG. 3 is a bottom perspective view of a mounting assembly of the solar panel assembly of FIG. 2;

[0033] FIG. 4 is a top perspective view of the mounting assembly of FIG. 3;

[0034] FIG. 5 is a perspective view of a spring clip of the mounting assembly of FIG. 4;

[0035] FIG. 6 is a sectional view of the spring clip of FIG. 5 taken at line VI-VI of FIG. 5;

[0036] FIG. 7 is an enlarged portion of the spring clip of FIG. 6;

[0037] FIG. 8 is a top view of the spring clip of FIG. 5;

[0038] FIG. 9 is a side view of the spring clip of FIG. 5;

[0039] FIG. 10 is a sectional view of the mounting assembly of FIG. 3 taken at lineX-X of FIG. 3;

[0040] FIG. 1 1 is a flowchart illustrating an example method of assembling the solar panel assembly of FIG. 1 ;

[0041] FIGS 12A-12C are sectional views of the mounting assembly of FIG. 3 illustrating the method of FIG. 11 ; FIG. 12A illustrates a bracket subassembly; FIG. 12B illustrates the bracket subassembly of FIG. 12A coupled to a solar panel; and FIG. 12C illustrates the solar panel assembly including the mounting bracket assembly fixed to the solar panel;

[0042] FIGS. 13A-13D are sequential sectional views of a mounting assembly illustrating assembly of the mounting assembly; FIG. 13A illustrates the mounting assembly in an uninstalled state; FIG. 13B illustrates the mounting assembly of in a first partially installed state; FIG. 13C illustrates the mounting assembly in a second partially installed state; and FIG. 13D illustrates the mounting assembly in an installed state.

[0043] Corresponding reference numerals indicate corresponding parts throughout the several views of the drawings.Attorney Docket No. 0275-001791 -WO-POADETAILED DESCRIPTION

[0044] Example embodiments will now be described more fully with reference to the accompanying drawings.

[0045] In at least one example embodiment, as shown in FIG. 1 , a solar panel assembly 100 includes a solar panel 102. The solar panel assembly 100 may be configured to rotate the solar panel 102 to track a location of the sun so as to maximize an amount of light absorbed. The solar panel 102 is coupled to a first or panel bracket 104. The panel bracket 104 is coupled to a second or carrier bracket 106, as will be described in greater detail below. The carrier bracket 106 is coupled to a horizontal support 108, such as by a strap 1 10.

[0046] The horizontal support 108 may be rotatably coupled to vertical supports 1 12. The horizontal support 108 may be operatively coupled to a motor (not shown). The motor may be configured to rotate the horizontal support 108 about a tracking axis 1 14. The solar panel 102 is configured to rotate together with the horizontal support 108, as shown by the arrow 1 16.

[0047] In at least one example embodiment, as shown in FIG. 2, the panel bracket 104 is coupled to an underside or rear surface 200 of the solar panel 102. The panel bracket 104 may be directly fixed to the solar panel 102, such as by an adhesive (not shown). The panel bracket 104 is coupled to the carrier bracket 106 by a spring clip 202, as will be described in greater detail below. The carrier bracket 106 is coupled to the horizontal support 108 by the strap 110. In at least the example embodiment shown, the horizontal support 108 is a tube. The carrier bracket 106 and horizontal support 108 include complementary locking features (see, e.g., boss 314 in FIG. 3) that reduce or prevent rotation of the carrier bracket 106 about the tracking axis 1 14.

[0048] In at least one example embodiment, a mounting assembly 300 includes the panel bracket 104, the carrier bracket 106, and the spring clip 202. The carrier bracket 106 includes a body 302 defining a carrier bracket interior region (see carrier bracket interior region 1000 in FIG. 10). The panel bracket 104 is disposed at least partially within the carrier bracket interior region.

[0049] The body 302 of the carrier bracket 106 defines a plurality of receptacles 304. The receptacles 304 may be through holes, as shown. In at least the example embodiment shown, the plurality of receptacles 304 includes two pairs of opposing receptacles 304. As will be discussed in greater detail below, each of the receptacles 304 is configured to receive a portion of a one of the spring clips 202, such as a protrusion 306 of the spring clip 202.Attorney Docket No. 0275-001791 -WO-POA

[0050] The body 302 of the carrier bracket 106 includes a first or center portion 308 and two second or end portions 310. The center portion 308 is longitudinally between the two end portions 310. Each of the end portions 310 may have a U-shaped cross section.

[0051] The center portion 308 includes a mating surface 312 configured to receive a portion of the horizontal support 108 (shown in FIG. 2). The mating surface 312 may have a partially cylindrical shape. The mating surface 312 may be configured to directly contact the horizontal support 108.

[0052] The center portion 308 further includes a boss 314. The boss 314 is configured to be at least partially received by a mating receptacle (not shown) in the horizontal support 108 to reduce or prevent rotation of the carrier bracket 106 about the tracking axis 1 14 (shown in FIGS. 1-2). In at least one other example embodiment, a carrier bracket may define a receptacle and a horizontal support may include a mating boss.

[0053] In at least one example embodiment, as shown in FIG. 4, the panel bracket 104 includes a body 400 defining a panel bracket interior region 402. The body 400 may have a U-shaped cross section. For example, the body 400 may include a bottom wall 404 and a pair of opposing side walls 406. The side walls 406 may be substantially perpendicular to the bottom wall 404 and substantially parallel to one another. The body 400 may further include a rounded corner 408 between the bottom wall 404 and each of the side walls 406.

[0054] The body 400 of the panel bracket 104 further includes a pair of flanges 410. Each of the flanges 410 extends from a respective one of the pair of side walls 406. Each of the flanges 410 may be substantially perpendicular to the respective one of the side walls 406. Each flange 410 includes a flange surface 412 configured to be coupled to the solar panel 102 (shown in FIGS. 1-2).

[0055] The spring clips 202 are disposed at least partially within the panel bracket interior region 402. At least a portion of each spring clip 202 extends through the panel bracket 104 and into one of the receptacles 304 of the carrier bracket 106, as will be described in greater detail below. Therefore, the solar panel 102 (shown in FIGS. 1-2) is coupled to the horizontal support (shown in FIGS. 1-2) via the spring clip 202.

[0056] In at least one example embodiment, as shown in FIG. 5, the spring clip 202 includes a pair of arms 500 and a base 502. Each of the arms 500 is configured to pivot independently of the other arm 500 with respect to the base 502. Therefore, the spring clip 202 is movable between a relaxed position, as shown, and a flexed position (shown in FIGS. 13B-13C) in which the arms 500 are pivoted toward one another. Absent an external force,Attorney Docket No. 0275-001791 -WO-POA the spring clip 202 is configured to automatically return to the relaxed position from the flexed position.

[0057] In at least one example embodiment, the spring clip 202 has a single-piece, unitary structure. The spring clip 202 may be formed from and / or include spring steel. For example, the spring steel may include SAE 1050 steel.

[0058] In at least one example embodiment, the base 502 extends between the pair of arms 500. The base 502 may be substantially planar (i.e., include two opposing flat / planar surfaces). The base 502 may be configured to directly contact the bottom wall 404 of the panel bracket 104 (shown in FIG. 4).

[0059] Each of the arms 500 includes a respective one of the protrusions 306. Each of the protrusions 306 may be hollow and define a protrusion interior region 504. Each of the protrusions 306 may further define an aperture 506.

[0060] In at least one example embodiment, each of the arms 500 includes a first or bottom portion 508, a second or middle portion 510, and a third or top portion 512. The bottom portion 508 is between the middle portion 510 and the base 502. The middle portion 510 is between the top portion 512 and the bottom portion 508. The bottom portion 508 is convex. The middle portion 510 is concave. The top portion 512 is substantially planar (i.e., includes two opposing flat / planar surfaces). The top portion 512 is substantially perpendicular to the base 502 when the spring clip 202 is in the relaxed position.

[0061] The top portion 512 of each of the arms 500 includes a mating surface 514. The mating surface 514 is configured to directly contact one of the side walls 406 of the panel bracket 104 (shown in FIG. 4).

[0062] In at least one example embodiment, the spring clip 202 is manufactured in a sheet metal operation. A method of manufacturing may include providing a flat rectangular sheet of metal (e.g., spring steel). The general shape of the spring clip 202 may be formed in a cold form drawing process.

[0063] Referring to FIG. 6, in at least one example embodiment, the spring clip 202 has a substantially uniform thickness 600. The thickness 600 may be greater than or equal to about 0.9 mm (e.g., greater than or equal to about 0.95 mm, greater than or equal to about 1 mm, greater than or equal to about 1.05 mm, greater than or equal to about 1.1 mm, greater than or equal to about 1 .15 mm, or greater than or equal to about 1 .2 mm).

[0064] As discussed above, the bottom portion 508 is convex and the middle portion 510 is concave. The bottom portion 508 may have a cross section that defines a portion of a circle. The bottom portion 508 includes a first inner diameter surface 602 and a first outerAttorney Docket No. 0275-001791 -WO-POA diameter surface 604. The middle portion 510 may have a cross section that defines a portion of a circle. The middle portion 510 includes a second inner diameter surface 606 and a second outer diameter surface 608.

[0065] The first inner diameter surface 602 defines a first radius of curvature. The second inner diameter surface 606 defines a second radius of curvature. A ratio of the second radius of curvature to the first radius of curvature may be greater than about 0.5 (e.g., greater than or equal to about 0.6, greater than or equal to about 0.7, greater than or equal to about 0.8, greater than or equal to about 0.9, greater than or equal to about 1 , greater than or equal to about 1.1 , greater than or equal to about 1 .2, greater than or equal to about 1 .3, greater than or equal to about 1 .4, greater than or equal to about 1 .5, greater than or equal to about 1 .6, greater than or equal to about 1 .7, greater than or equal to about 1 .8, or greater than or equal to about 1 .9). The ratio of the second radius of curvature to the first radius of curvature may be less than or equal to about 2 (e.g., less than or equal to about 1 .9, less than or equal to about 1 .8, less than or equal to about 1 .7, less than or equal to about 1 .6, less than or equal to about 1 .5, less than or equal to about 1 .4, less than or equal to about 1 .3, less than or equal to about 1 .2, less than or equal to about 1 .1 , less than or equal to about 1 , less than or equal to about 0.9, less than or equal to about 0.8, less than or equal to about 0.7, or less than or equal to about 0.6). In at least the example embodiment shown, the first radius of curvature is smaller than the second radius of curvature. In at least one other example embodiment, a first radius of curvature of a bottom portion may be greater than a second radius of curvature of a middle portion.

[0066] An outer arm surface 610 includes the mating surface 514, the second inner diameter surface 606, and the first outer diameter surface 604. An inner arm surface 612 includes a planar surface 614 of the top portion 512, the second outer diameter surface 608, and the first inner diameter surface 602.

[0067] With reference to FIG. 7, each of the protrusions 306 includes a first protrusion surface 700. The first protrusion surface 700 may be configured to engage another surface to move the spring clip 202 (shown in FIGS. 1-6) from the relaxed position to the flexed position. For example, the first protrusion surface 700 is configured to engage a surface of the panel bracket 104 (shown in FIGS. 1-4) during assembly of the spring clip 202 to the panel bracket 104, as described in the discussion accompanying FIG. 12A. The first protrusion surface 700 is configured to engage a surface of the carrier bracket 106 (shown in FIGS. 1 -4) during assembly of the spring clip 202 and the panel bracket 104 to the carrier bracket 106, as described in the discussion accompanying FIGS. 13A-13D.Attorney Docket No. 0275-001791 -WO-POA

[0068] The first protrusion surface 700 defines a first angle 702 with respect to the outer arm surface 610 (or, more specifically, with respect to the mating surface 514 in the example shown). The first angle 702 is oblique (e.g., acute). For example, the first angle 702 may be greater than or equal to about 5° (e.g., greater than or equal to about 10°, greater than or equal to about 15°, greater than or equal to about 20°, greater than or equal to about 25°, greater than or equal to about 30°, greater than or equal to about 35°, greater than or equal to about 40°, greater than or equal to about 45°, greater than or equal to about 50°, greater than or equal to about 55°, greater than or equal to about 60°, greater than or equal to about 65°, greater than or equal to about 70°, greater than or equal to about 75°, or greater than or equal to about 80°). The first angle 702 may be less than or equal to about 85° (e.g., less than or equal to about 80°, less than or equal to about 75°, less than or equal to about 70°, less than or equal to about 65°, less than or equal to about 60°, less than or equal to about 55°, less than or equal to about 50°, less than or equal to about 45°, less than or equal to about 40°, less than or equal to about 35°, less than or equal to about 30°, less than or equal to about 25°, less than or equal to about 20°, less than or equal to about 15°, or less than or equal to about 10°).

[0069] In at least one example embodiment, each of the protrusions 306 further includes a second protrusion surface 704. The second protrusion surface 704 defines a second angle 706 with respect to the outer arm surface 610 (or, more specifically, with respect to the mating surface 514 in the example shown). The second angle 706 is oblique (e.g., acute). For example, the second angle 706 may be greater than or equal to about 5° (e.g., greater than or equal to about 10°, greater than or equal to about 15°, greater than or equal to about 20°, greater than or equal to about 25°, greater than or equal to about 30°, greater than or equal to about 35°, greater than or equal to about 40°, greater than or equal to about 45°, greater than or equal to about 50°, greater than or equal to about 55°, greater than or equal to about 60°, greater than or equal to about 65°, greater than or equal to about 70°, greater than or equal to about 75°, or greater than or equal to about 80°). The second angle 706 may be less than or equal to about 85° (e.g., less than or equal to about 80°, less than or equal to about 75°, less than or equal to about 70°, less than or equal to about 65°, less than or equal to about 60°, less than or equal to about 55°, less than or equal to about 50°, less than or equal to about 45°, less than or equal to about 40°, less than or equal to about 35°, less than or equal to about 30°, less than or equal to about 25°, less than or equal to about 20°, less than or equal to about 15°, or less than or equal to about 10°).Attorney Docket No. 0275-001791 -WO-POA

[0070] In at least one example embodiment, each of the protrusions 306 may further include a third protrusion surface 708. The third protrusion surface 708 is substantially perpendicular to the outer arm surface 610. The third protrusion surface 708 is configured to engage another surface to reduce or prevent movement of the spring clip 202 in a first or upward direction 710 when the spring clip 202 is assembled to the panel bracket 104 and carrier bracket 106 (both shown in FIGS. 1-4), as will be described in greater detail below in the discussion accompanying FIG. 10. The protrusion 306 is smooth and / or rounded between the first and third protrusions surfaces 700, 708.

[0071] In at least one example embodiment, each of the protrusions 306 may further include a fourth protrusion surface 712. The fourth protrusion surface 712 is substantially perpendicular to the outer arm surface 610 and parallel to the third protrusion surface 708. The fourth protrusion surface 712 is configured to engage another surface to reduce or prevent movement of the spring clip 202 in a second or downward direction 714 when the spring clip 202 is assembled to the panel bracket 104 and carrier bracket 106 (both shown in FIGS. 1-4), as will be described in greater detail below in the discussion accompanying FIG. 10. The protrusion is smooth and / or rounded between the second and fourth protrusion surfaces 704, 712.

[0072] The protrusion 306 defines a center plane 716 between the first and second protrusion surfaces 700, 704. In at least the example embodiment shown, the protrusion 306 is asymmetric about the center plane 716. This, the first and second angles 702, 706 are different. In at least one other example embodiment, a protrusion is symmetric about a center plane and first and second angles are the same. As shown in FIG. 7, the center plane 716 also defines a longitudinal axis of the protrusion 306, and the first and second protrusion surfaces 700, 704 may be considered axial end surfaces of the protrusion 306.

[0073] In at least one example embodiment, as shown in FIG. 8, the spring clip 202 has a non-uniform width. For example the base 502 defines a first width 800 and the top portion 512 of the arms 500 defines a second width 802. The second width 802 is greater than the first width 800.

[0074] In at least one example embodiment, as shown in FIG. 9, the bottom and middle portions 508, 510 of each of the arms 500 define the first width 800. Thus, the base 502 (shown in FIG. 8), bottom portion 508, and middle portion 510 may have a uniform width. The top portion 512 defines a substantially rectangular shape having rounded cornersAttorney Docket No. 0275-001791 -WO-POA

[0075] As discussed above and shown in FIG. 10, the mounting assembly 300 includes the panel bracket 104, the carrier bracket 106, and the spring clip 202. At least a portion of the panel bracket 104 is in a carrier bracket interior region 1000, and at least a portion of the spring clip 202 is in the panel bracket interior region 402. Each of the protrusions 306 of the spring clip 202 extends through an aperture 1002 in the panel bracket 104 and the receptacles 304 in the carrier bracket 106 to couple the panel bracket 104 (and solar panel 102, shown in FIGS. 1-2) to the carrier bracket 106.

[0076] The protrusions 306 are configured to engage the panel bracket 104 during assembly of the spring clip 202 to the panel bracket 104. For example, the first protrusion surfaces 700 of the protrusions 306 engage an inner panel bracket surface 1004, as will be described in greater detail in the discussion accompanying FIG. 12A.

[0077] The aperture 1002 of the panel bracket 104 is at least partially defined by an aperture surface 1006. The receptacle 304 of the carrier bracket 106 is at least partially defined by a receptacle surface 1008. The third protrusion surface 708 is configured to engage the aperture surface 1006 and / or the receptacle surface 1008 to reduce or prevent movement of spring clip 202 in the upward direction 710. The fourth protrusion surface 712 is configured to engage the aperture surface 1006 and / or the receptacle surface 1008 to reduce or prevent movement of spring clip 202 in the downward direction 714.

[0078] The bottom wall 404 of the panel bracket 104 contacts the body 302 of the carrier bracket 106. The bottom wall 404 of the panel bracket 104 may directly contact the body 302 of the carrier bracket 106. The base 502 of the spring clip 202 contacts the bottom wall 404 of the panel bracket 104. The base 502 of the spring clip 202 may directly contact the bottom wall 404 of the panel bracket 104.

[0079] In at least one example embodiment, the base 502 of the spring clip 202 may be fixed to the bottom wall 404, as will be discussed in greater detail below in the discussion accompanying FIG. 12B. The base 502 of the spring clip 202 may be directly fixed to the bottom wall 404. This attachment may be in addition to the coupling of the spring clip 202 to the panel bracket 104 via the protrusions 306 in the apertures 1002.

[0080] In at least one example embodiment, the base 502 of the spring clip 202 extends across substantially an entire transverse dimension 1010 of the panel bracket interior region 402. For example, the base 502 may extend across greater than or equal to about 70% of the transverse dimension 1010 (e.g., greater than or equal about 75%, greater than or equal about 80%, greater than or equal about 85%, greater than or equal about 90%, greater than or equal about 95%, or greater than or equal about 98%). The transverseAttorney Docket No. 0275-001791 -WO-POA dimension 1010 extends from the inner panel bracket surface 1004 on one of the side walls 406 to the inner panel bracket surface 1004 on the other one of the side walls 406.

[0081] At least one example embodiment relates to a method of assembly a solar panel assembly, as shown in FIG. 1 1. The method generally includes assembling a mounting subassembly at S1 100; coupling a solar panel to the mounting subassembly at S1 104; and assembling a solar panel assembly at S1 108. Each of these steps is discussed in greater detail below in the context of the solar panel assembly 100 of FIGS. 1-2.

[0082] As shown in FIG. 12A, a mounting subassembly 1200 includes the panel bracket 104 and the spring clip 202. At S1 100, assembling the mounting subassembly 1200 includes moving the spring clip 202 from a relaxed position, as shown, to a flexed position (shown in FIGS. 13B-13C); inserting the spring clip 202 into the panel bracket interior region 402; and returning the spring clip 202 from the flexed position to the relaxed position.

[0083] Moving the spring clip 202 from the relaxed position to the flexed position may include translating the spring clip 202 in the downward direction 714 such that the first protrusion surfaces 700 of the protrusions 306 engage the inner panel bracket surface 1004, thereby forcing the arms 500 of the spring clip 202 to pivot inward toward one another. Inserting the spring clip 202 into the panel bracket interior region 402 may include continuing to translate the spring clip 202 in the downward direction 714 while the protrusions 306 slides along the inner panel bracket surface 1004. Moving the spring clip 202 from the flexed position to the relaxed position may include continuing to translate the spring clip 202 in the downward direction 714 until the protrusion 306 reaches the aperture 1002. When the protrusion 306 reaches the aperture 1002, thereby clearing the side wall 406, the spring clip 202 automatically returns to the relaxed position and / or “snaps” into place with the protrusions 306 extending through respective apertures 1002. The spring clip 202 may be translated in the downward direction 714 until the base 502 of the spring clip 202 contacts the bottom wall 404 of the panel bracket 104.

[0084] In at least one other example embodiment, since a top 1202 of the panel bracket 104 is open and the panel bracket interior region 402 is accessible, the spring clip 202 may be moved from the relaxed position to the flexed position without contacting the panel bracket 104. For example, an operator and / or tool may pinch and / or squeeze the arms 500 toward one another while inserting the spring clip 202 into the panel bracket interior region 402. The operator and / or tool may release the arms 500 when the protrusions 306 are aligned with the apertures 1002 such that the arms move outwardly, returning to the relaxed position, with the protrusions 306 in respective apertures 1002.Attorney Docket No. 0275-001791 -WO-POA

[0085] In at least one example embodiment, S1100 further includes fixing the base 502 of the spring clip 202 to the bottom wall 404 of the panel bracket 104. The base 502 and bottom wall 404 may be coupled using one or more welds, a fastener (e.g., a selfpiercing rivet), an adhesive, a feature integral to the spring clip 202 and / or the panel bracket 104, or any combination thereof.

[0086] At S1 104, the method includes coupling the solar panel 102 to the mounting subassembly 1200. With reference to FIG. 12B, coupling the solar panel 102 to the mounting subassembly 1200 may include fixing the underside surface 200 of the solar panel 102 to the flange surface 412 of the panel bracket 104, such as by applying a layer of adhesive between the underside surface 200 and the flange surface 412.

[0087] At S1108, the method includes assembling the solar panel assembly 100 including the solar panel 102, the mounting subassembly 1200, and the carrier bracket 106, as shown in FIG. 12C. S1 108 generally includes engaging the protrusions 306 of the spring clip 202 with the carrier bracket 106 to move the spring clip 202 from the relaxed position to the flexed position; aligning the protrusions 306 of the spring clip 202 with respective receptacles 304 of the carrier bracket 106; and returning the spring clip 202 from the flexed position to the relaxed position.

[0088] As shown in FIG. 13A, S1108 includes longitudinally aligning the protrusions 306 of the spring clip 202 with respective receptacles 304 of the panel bracket 104 (e.g., along a first axis that is perpendicular to the upward and downward directions 710, 714, along a length of the panel bracket 104). Referring to FIG. 13B, S1 108 may include translating the mounting subassembly 1200 in the downward direction 714 (e.g., along a second axis that is parallel to the upward and downward directions 710, 714). As the mounting subassembly 1200 is translated, the protrusions 306 contact the carrier bracket 106. Specifically, the first protrusion surfaces 700 of the protrusions 306 contact an inner carrier bracket surface 1300. During translation, engagement of the surfaces 700, 1300 forces the arms 500 of the spring clip 202 inward such that the spring clip 202 is moved from the relaxed position to a flexed position, as shown in FIG. 13C. The first protrusion surfaces 700 slide along the inner carrier bracket surface 1300. When the protrusions 306 reach the receptacles 304 of the carrier bracket 106 (e.g., are aligned with the receptacles 304 along the second axis), the inner carrier bracket surface 1300 no longer forces the protrusions 306 inward, and the spring clip 202 automatically returns to the relaxed position. In the relaxed position, the protrusions 306 are at least partially within the receptacles 304 to couple the mounting subassembly 1200 to the carrier bracket 106, as shown in FIG. 13D.Attorney Docket No. 0275-001791 -WO-POA

[0089] In at least one example embodiment, the mounting subassembly 1200 is removable from the carrier bracket 106. The mounting subassembly 1200 may be removed from the carrier bracket 106 by pinching and / or squeezing the protrusions 306 toward one another, such as by an operator and / or tool, to place the spring clip 202 in the flexed position. With the spring clip 202 in the flexed position, the mounting subassembly 1200 may be translated in the upward direction 710 (shown in FIG. 10) and removed from the carrier bracket interior region 1000.

[0090] Example embodiments are provided so that this disclosure will be thorough, and will fully convey the scope to those who are skilled in the art. Numerous specific details are set forth such as examples of specific compositions, components, devices, and methods, to provide a thorough understanding of embodiments of the present disclosure. It will be apparent to those skilled in the art that specific details need not be employed, that example embodiments may be embodied in many different forms and that neither should be construed to limit the scope of the disclosure. In some example embodiments, well- known processes, well-known device structures, and well-known technologies are not described in detail.

[0091] The terminology used herein is for the purpose of describing particular example embodiments only and is not intended to be limiting. As used herein, the singular forms “a,” “an,” and “the” may be intended to include the plural forms as well, unless the context clearly indicates otherwise. The terms “comprises,” “comprising,” “including,” and “having,” are inclusive and therefore specify the presence of stated features, elements, compositions, steps, integers, operations, and / or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and / or groups thereof. Although the open-ended term “comprising,” is to be understood as a non-restrictive term used to describe and claim various embodiments set forth herein, in certain aspects, the term may alternatively be understood to instead be a more limiting and restrictive term, such as “consisting of” or “consisting essentially of.” Thus, for any given embodiment reciting compositions, materials, components, elements, features, integers, operations, and / or process steps, the present disclosure also specifically includes embodiments consisting of, or consisting essentially of, such recited compositions, materials, components, elements, features, integers, operations, and / or process steps. In the case of “consisting of,” the alternative embodiment excludes any additional compositions, materials, components, elements, features, integers, operations, and / or process steps, while in the case of “consisting essentially of,” any additional compositions,Attorney Docket No. 0275-001791 -WO-POA materials, components, elements, features, integers, operations, and / or process steps that materially affect the basic and novel characteristics are excluded from such an embodiment, but any compositions, materials, components, elements, features, integers, operations, and / or process steps that do not materially affect the basic and novel characteristics can be included in the embodiment.

[0092] Any method steps, processes, and operations described herein are not to be construed as necessarily requiring their performance in the particular order discussed or illustrated, unless specifically identified as an order of performance. It is also to be understood that additional or alternative steps may be employed, unless otherwise indicated.

[0093] When a component, element, or layer is referred to as being “on,” “engaged to,” “connected to,” or “coupled to” another element or layer, it may be directly on, engaged, connected, or coupled to the other component, element, or layer, or intervening elements or layers may be present. In contrast, when an element is referred to as being “directly on,” “directly engaged to,” “directly connected to,” or “directly coupled to” another element or layer, there may be no intervening elements or layers present. Other words used to describe the relationship between elements should be interpreted in a like fashion (e.g., “between” versus “directly between,” “adjacent” versus “directly adjacent,” etc.). As used herein, the term “and / or” includes any and all combinations of one or more of the associated listed items.

[0094] Although the terms first, second, third, etc. may be used herein to describe various steps, elements, components, regions, layers and / or sections, these steps, elements, components, regions, layers and / or sections should not be limited by these terms, unless otherwise indicated. These terms may be only used to distinguish one step, element, component, region, layer or section from another step, element, component, region, layer, or section. Terms such as “first,” “second,” and other numerical terms when used herein do not imply a sequence or order unless clearly indicated by the context. Thus, a first step, element, component, region, layer, or section discussed below could be termed a second step, element, component, region, layer or section without departing from the teachings of the example embodiments.

[0095] Spatially or temporally relative terms, such as “before,” “after,” “inner,” “outer,” “beneath,” “below,” “lower,” “above,” “upper,” and the like, may be used herein for ease of description to describe one element or feature's relationship to another element(s) or feature(s) as illustrated in the figures. Spatially or temporally relative terms may be intendedAttorney Docket No. 0275-001791 -WO-POA to encompass different orientations of the device or system in use or operation in addition to the orientation depicted in the figures.

[0096] Throughout this disclosure, the numerical values represent approximate measures or limits to ranges to encompass minor deviations from the given values and embodiments having about the value mentioned as well as those having exactly the value mentioned. Other than in the working examples provided at the end of the detailed description, all numerical values of parameters (e.g., of quantities or conditions) in this specification, including the appended claims, are to be understood as being modified in all instances by the term “about” whether or not “about” actually appears before the numerical value. “About” indicates that the stated numerical value allows some slight imprecision (with some approach to exactness in the value; approximately or reasonably close to the value; nearly). If the imprecision provided by “about” is not otherwise understood in the art with this ordinary meaning, then “about” as used herein indicates at least variations that may arise from ordinary methods of measuring and using such parameters. For example, “about” may comprise a variation of less than or equal to 5%, optionally less than or equal to 4%, optionally less than or equal to 3%, optionally less than or equal to 2%, optionally less than or equal to 1 %, optionally less than or equal to 0.5%, and in certain aspects, optionally less than or equal to 0.1 %. In addition, disclosure of ranges includes disclosure of all values and further divided ranges within the entire range, including endpoints and sub-ranges given for the ranges.

[0097] The foregoing description of the embodiments has been provided for purposes of illustration and description. It is not intended to be exhaustive or to limit the disclosure. Individual elements or features of a particular embodiment are generally not limited to that particular embodiment, but, where applicable, are interchangeable and can be used in a selected embodiment, even if not specifically shown or described. The same may also be varied in many ways. Such variations are not to be regarded as a departure from the disclosure, and all such modifications are intended to be included within the scope of the disclosure.

Claims

Attorney Docket No. 0275-001791 -WO-POACLAIMSWhat is claimed is:1 . A spring clip for a mounting assembly of a solar panel, the spring clip comprising: a base; a pair of arms extending from the base, each of the pair of arms being independently pivotable with respect to the base and including an outer arm surface; and a pair of protrusions on the pair of arms, respectively, each of the pair of protrusions including a first protrusion surface, a first angle between the first protrusion surface and the outer arm surface being oblique.

2. The spring clip of claim 1 , wherein the first angle ranges from 5° to 45°.

3. The spring clip of claim 2, wherein the first angle ranges from 15° to 35°.

4. The spring clip of any of the preceding claims, wherein: each of the pair of protrusions further includes a second protrusion surface, a second angle between the second protrusion surface and the outer arm surface being oblique.

5. The spring clip of claim 4, wherein the second angle ranges from 15° to 55°.

6. The spring clip of any of claims 4-5, wherein each of the protrusions further includes a third protrusion surface and a fourth protrusion surface, the third protrusion surface is between the outer arm surface and the second protrusion surface, and the fourth protrusion surface is between the outer arm surface and the first protrusion surface.

7. The spring clip of claim 6, wherein the third protrusion surface is perpendicular to the outer arm surface, and the fourth protrusion surface is perpendicular to the outer arm surface.

8. The spring clip of any of the preceding claims, whereinAttorney Docket No. 0275-001791 -WO-POA each of the pair of arms includes a first portion and a second portion, the first portion is between the second portion and the base, and the first portion is convex.

9. The spring clip of claim 8, wherein the second portion is concave.

10. The spring clip of claim 9, wherein the first portion includes a first inner diameter surface defining a first radius of curvature, the second portion include a second inner diameter surface defining a second radius of curvature, and the first radius of curvature is less than the second radius of curvature.1 1. The spring clip of any of claims 8-10, wherein each of the pair of arms further includes a third portion, and the second portion is between the first portion and the third portion.

12. The spring clip of claim 1 1 , wherein the third portion is planar and includes a portion of the outer arm surface that forms the first angle with the first protrusion surface.

13. The spring clip of any of the preceding claims, wherein the spring clip is a singlepiece, unitary structure.

14. The spring clip of any of the preceding claims, wherein the spring clip has a thickness of greater than or equal to 0.9 mm.

15. The spring clip of any of the preceding claims, wherein the spring clip has a uniform thickness.

16. A mounting assembly for a solar panel comprising: a bracket configured to be fixed to a solar panel, the bracket including a wall at least partially defining an interior region, the wall defining a pair of apertures; and a spring clip at least partially in the interior region of the bracket, the spring clip including a base and a pair of arms extending from the base, each of the arms including aAttorney Docket No. 0275-001791 -WO-POA protrusion and being pivotable with respect to the base, the spring clip being movable between a relaxed position in which the pair of protrusions are at least partially in the pair of apertures, respectively, and a flexed position in which the protrusions are outside of the apertures.

17. The mounting assembly of claim 16, wherein each of the protrusions is configured to engage a surface of a respective one of the apertures to prevent movement of the spring clip with respect to the bracket.

18. The mounting assembly of any of claims 16-17, wherein the interior region defines a transverse dimension, and the base of the spring clip extends across greater than or equal to about 90% of the transverse dimension.

19. The mounting assembly of any of claims 16-18, wherein the base of the spring clip is directly engaged to a wall of the bracket.

20. A method of assembling a solar panel to a structure, the method comprising: aligning a protrusion of a mounting assembly with a receptacle of a carrier bracket along a first axis, the mounting assembly including a bracket and a spring clip, the bracket defining an aperture, the spring clip including a pivotable arm and the protrusion, the protrusion extending through the aperture; translating the mounting assembly with respect to the carrier bracket along a second axis perpendicular to the first axis such that the protrusion engages a surface of the carrier bracket to move the spring clip from a relaxed position to a flexed position; and aligning the protrusion with the receptacle along the second axis such that the spring clip moves from the flexed position to the relaxed position and the protrusion extends at least partially into the receptacle.

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