US-12620931-B2 - Clamping mechanism for grounding photovoltaic module(s)

US12620931B2US 12620931 B2US12620931 B2US 12620931B2US-12620931-B2

Abstract

A clamping mechanism includes a first fastener and a second fastener. The second fastener includes a head having a first rib with a first serration, a second rib with a second serration, a third rib with a third serration, and a fourth rib with a fourth serration. The first rib extends a first length and the first serration extends a second length that is less than the first length. The second rib extends a third length and the second serration extends a fourth length that is less than the third length. The third rib extends a fifth length and the third serration extends a sixth length that is less than the fifth length. The fourth rib extends a seventh length and the fourth serration extends an eighth length that is less than the seventh length. The second fastener includes a body coupled to the first fastener.

Inventors

Klaus NICOLAEDIS
Todd Ganshaw

Assignees

UNIRAC, INC.

Dates

Publication Date: 20260505
Application Date: 20230426

Claims (20)

1 . A clamping mechanism configured to clamp a photovoltaic module to a rail, the clamping mechanism comprising: a first fastener; and a second fastener including: a first end having a head configured to reside within a channel of the rail, the head including: a first rib extending in a length direction along an upper surface of the head and protruding above the upper surface to a first height along the length direction, a first serration disposed on the first rib at an outermost side edge of the first rib, the first serration extending upwardly away from a length direction of the first rib and toward the first fastener, such that: the first serration extends from the first height to a second height that is higher than the first height, and upon actuation of the clamping mechanism, the first serration engages with an inner surface of the rail; a second rib, a second serration disposed on the second rib, a third rib, a third serration disposed on the third rib, a fourth rib, and a fourth serration disposed on the fourth rib; and a second end having a body coupled to the first fastener.
2 . The clamping mechanism of claim 1 , wherein: the body extends from the head; the first rib and the second rib are disposed on a first side of the body; and the third rib and the fourth rib are disposed on a second side of the body.
3 . The clamping mechanism of claim 1 , wherein: the first rib has a first length; the first serration has a second length that is less than the first length; the second rib has a third length; the second serration has a fourth length that is less than the third length; the third rib has a fifth length; the third serration has a sixth length that is less than the fifth length; the fourth rib has a seventh length; and the fourth serration has an eighth length that is less than the seventh length.
4 . The clamping mechanism of claim 1 , wherein: the second serration extends from the second rib; the third serration extends from the third rib; and the fourth serration extends from the fourth rib.
5 . The clamping mechanism of claim 1 , wherein at least one of the first serration, the second serration, the third serration, or the fourth serration is configured to pierce a dielectric layer of the rail.
6 . The clamping mechanism of claim 1 , wherein each of the first serration, the second serration, the third serration, or the fourth serration is located at a perimeter of the head, the perimeter extending around an outermost side edge of the head.
7 . The clamping mechanism of claim 1 , wherein: the first rib is disposed from a surface of the head by a first distance; the first serration is disposed from the surface by a second distance that is greater than the first distance; the second rib is disposed from the surface by a third distance; the second serration is disposed from the surface by a fourth distance that is greater than the third distance; the third rib is disposed from the surface by a fifth distance; the third serration is disposed from the surface by a sixth distance that is greater than the fifth distance; the fourth rib is disposed from the surface by a seventh distance; and the fourth serration is disposed from the surface by an eighth distance that is greater than the seventh distance.
8 . A clamping mechanism comprising: a first fastener including: a head having: a first rib with a first serration, the first rib extending a first length along an upper surface of the head and up to a first height, the first serration extending a second length that is less than the first length, and the first serration extending from the first rib, at an outermost side edge of the first rib, and to a second height that is greater than the first height of the first rib, a second rib with a second serration, the second rib extending a third length and the second serration extending a fourth length that is less than the third length, a third rib with a third serration, the third rib extending a fifth length and the third serration extending a sixth length that is less than the fifth length, and a fourth rib with a fourth serration, the fourth rib extending a seventh length and the fourth serration extending an eighth length that is less than the seventh length; and a body configured to couple to a second fastener, wherein, upon actuation of the clamping mechanism to clamp an object between the first fastener and the second fastener, the first serration engages with the object before the first rib.
9 . The clamping mechanism of claim 8 , further comprising: the second fastener; and a third fastener, wherein: the first fastener couples to a first end of the second fastener; and the third fastener couples to a second end of the second fastener, the second end being opposite the first end.
10 . The clamping mechanism of claim 8 , wherein: the first length has a first cross-sectional shape; the second length has a second cross-sectional shape that is different than the first cross-sectional shape; the third length has a third cross-sectional shape; the fourth length has a fourth cross-sectional shape that is different than the third cross-sectional shape; the fifth length has a fifth cross-sectional shape; the sixth length has a sixth cross-sectional shape that is different than the fifth cross-sectional shape; the seventh length has a seventh cross-sectional shape; and the eighth length has an eighth cross-sectional shape that is different than the seventh cross-sectional shape.
11 . The clamping mechanism of claim 10 , wherein: at least two of the first cross-sectional shape, the third cross-sectional shape, the fifth cross-sectional shape, and the seventh cross-sectional shape are identical; and at least two of the second cross-sectional shape, the fourth cross-sectional shape, the sixth cross-sectional shape, and the eighth cross-sectional shape are identical.
12 . The clamping mechanism of claim 10 , wherein at least one of: the first length and the seventh length are identical; the second length and the eighth length are identical; the third length and the fifth length are identical; or the fourth length and the sixth length are identical.
13 . The clamping mechanism of claim 8 , wherein: the first length is defined above a surface of the head by the first height; the second length is defined above the surface by the second height that is greater than the first height; the third length is defined above the surface by a third height; the fourth length is defined above the surface by a fourth height that is greater than the third height; the fifth length is defined above the surface by a fifth height; the sixth length is defined above the surface by a sixth height that is greater than the fifth height; the seventh length is defined above the surface by a seventh height; and the eighth length is defined above the surface by an eighth height that is greater than the seventh height.
14 . The clamping mechanism of claim 8 , wherein: the first rib and the second rib are disposed on a first side of the body; and the third rib and the fourth rib are disposed on a second side of the body.
15 . A clamping mechanism comprising: a first fastener; and a second fastener attached to the first fastener, the second fastener comprising: a body configured to couple the second fastener to the first fastener, and a head coupled to the body, the head including at least one rib disposed on the body, and at least one serration disposed on the at least one rib at an outermost side edge of the at least one rib, the at least one serration extending higher than a highest point of the at least one rib.
16 . The clamping mechanism of claim 15 , wherein: the at least one rib comprises: a first rib disposed on a first side of the body; a second rib disposed on the first side of the body; a third rib disposed on a second side of the body; and a fourth rib disposed on the second side of the body.
17 . The clamping mechanism of claim 16 , wherein: the at least one serration comprises: a first serration extending from the first rib; a second serration extending from the second rib; a third serration extending from the third rib; and a fourth serration extending from the fourth rib.
18 . The clamping mechanism of claim 17 , wherein: the first rib has a first length; the first serration has a second length that is less than the first length; the second rib has a third length; the second serration has a fourth length that is less than the third length; the third rib has a fifth length; the third serration has a sixth length that is less than the fifth length; the fourth rib has a seventh length; and the fourth serration has an eighth length that is less than the seventh length.
19 . The clamping mechanism of claim 17 , wherein: at least one of the first serration, the second serration, the third serration, or the fourth serration is configured to pierce a dielectric layer of a rail; and at least one of the first serration, the second serration, the third serration, or the fourth serration is located proximate to a perimeter of the head.
20 . The clamping mechanism of claim 17 , wherein: the first rib is disposed from a surface of the head by a first distance; the first serration is disposed from the surface by a second distance that is greater than the first distance; the second rib is disposed from the surface by a third distance; the second serration is disposed from the surface by a fourth distance that is greater than the third distance; the third rib is disposed from the surface by a fifth distance; the third serration is disposed from the surface by a sixth distance that is greater than the fifth distance; the fourth rib is disposed from the surface by a seventh distance; and the fourth serration is disposed from the surface by an eighth distance that is greater than the seventh distance.

Description

BACKGROUND The solar industry is growing world-wide and, as a result, more-efficient structures are desirable for mounting photovoltaic modules or solar panel modules to a structure, such as a roof of a home or other building. Unfortunately, because solar panel modules have not been standardized, a size (e.g., thickness) of the solar panel modules may vary depending on the manufacturer. As such, racks, rails, or other mounting systems are customized according to the size of the solar panel modules. However, in order to comply with codes and/or other regulations (e.g., National Electric Code NEC)), the mounting systems may need to be bonded and/or grounded. However, because the thickness of the solar panels may vary depending on the manufacture, bonding and/or grounding the solar panel modules remains a challenge. In such instances, the mounting systems may fail to electrically bond or ground the solar panel modules, and/or the installation may be difficult and/or time consuming. BRIEF DESCRIPTION OF THE DRAWINGS The detailed description is described with reference to the accompanying figures. In the figures, the left-most digit(s) of a reference number identifies the figure in which the reference number first appears. The use of the same reference numbers in different figures indicates similar or identical components or features. The components, devices, and/or apparatuses depicted in the accompanying figures are not to scale and components within the figures may be depicted not to scale with each other. FIG. 1 illustrates a perspective view of an example clamping mechanism for use with a photovoltaic module, according to embodiments of the present disclosure. FIG. 2 illustrates an exploded view of the clamping mechanism of FIG. 1, showing a first fastener, a second fastener, and a third fastener of the clamping mechanism, according to embodiments of the present disclosure. FIG. 3 illustrates a cross-section view of the clamping mechanism of FIG. 1, taken along line A-A of FIG. 1, according to embodiments of the present disclosure. FIG. 4 illustrates a perspective view of the third fastener of FIG. 2, according to embodiments of the present disclosure. FIG. 5A illustrates a first side view of the third fastener of FIG. 2, according to embodiments of the present disclosure. FIG. 5B illustrates a second side view of the third fastener of FIG. 2, according to embodiments of the present disclosure. FIG. 6A illustrates a third side view of the third fastener of FIG. 2, according to embodiments of the present disclosure. FIG. 6B illustrates a fourth side view of the third fastener of FIG. 2, according to embodiments of the present disclosure. FIG. 7A illustrates a detailed view of example first ribs and first serrations of the third fastener of FIG. 2, according to embodiments of the present disclosure. FIG. 7B illustrates a detailed view of example second ribs and second serrations of the third fastener of FIG. 2, according to embodiments of the present disclosure. FIG. 8A illustrates a cross-sectional view of the third fastener of FIG. 2, taken along line B-B of FIG. 5B, showing details of the second ribs and the second serrations of FIG. 7B, according to embodiments of the present disclosure. FIG. 8B illustrates a side view of the third fastener of FIG. 2, showing a detailed view of the second ribs and the second serrations of FIG. 7B, according to embodiments of the present disclosure. FIG. 9A illustrates a cross-sectional view of the third fastener of FIG. 2, taken along line C-C of FIG. 5A, according to embodiments of the present disclosure. FIG. 9B illustrates a cross-sectional view of the third fastener of FIG. 2, taken along line D-D of FIG. 5A, according to embodiments of the present disclosure. FIG. 10 illustrates an example use of the clamping mechanism of FIG. 1, according to embodiments of the present disclosure. FIG. 11 illustrates an example use of the clamping mechanism of FIG. 1, according to embodiments of the present disclosure. FIG. 12 illustrates an example use of the clamping mechanism of FIG. 1, according to embodiments of the present disclosure. DETAILED DESCRIPTION This application is directed, at least in part, to a clamping mechanism that attaches to a rail, bracket, and/or other mounting equipment of a photovoltaic module, and which electrically bonds the photovoltaic module to the mounting equipment. In some embodiments, the mounting equipment may be disposed on a surface (e.g., roof, etc.) to which the photovoltaic module is disposed. For example, rails may be mounted to the structure, and thereafter, the photovoltaic module may be mounted to the rails. The clamping mechanism may serve to couple the photovoltaic module to the rails, as well as electrically bond the photovoltaic module to the rails, for example, when the clamping mechanism is tightened. In some embodiments, portions of the clamping mechanism include ribs that increase a clamping force of the clamping mechanism to the