Module attachment apparatus and method

Abstract

Exemplary systems and methods described herein can be used to secure a rail to a module or the rail to a support using a nut that can be inserted at a desired point of mounting. Another exemplary system describes a flashing to be inserted under a roof shingle, wherein the flashing is secured to a support for a rail or module. Yet another exemplary system describes a clamp that secures a rail or module and is adjustable along the length of a post. Spacers can be added to the post to extend the adjustment range of the clamp.

Claims

1. An assembly comprising: a base; a post secured to and extending from the base; a clamp configured for securing a rail, module, or supporting component to the post, the clamp comprising: a post-receiving component comprising a post-receiving aperture receiving the post, the post receiving component forming a living hinge for the clamp; a first flange comprising a flat edge and a tapered edge; a second flange, comprising a flat edge and a tapered edge, wherein each of the first and second flanges abuts the post-receiving aperture at a proximal end and tapers away from each other towards a distal end, and wherein the flat edge of each of the first and second flanges is coplanar with a respective planar portion of an outer surface of the post-receiving component to form two contiguous planar outer surfaces; a void between the proximal ends of the first and second flanges, wherein the void abuts the post-receiving aperture; and a securing aperture for receiving a securing component for securing the rail, module, or supporting component to the clamp; wherein rotating the securing component causes the first flange to approach the second flange and decrease the size of the post-receiving aperture by articulation of the living hinge, and wherein the securing component extends through the securing aperture and the void to secure the rail, module, or supporting component to at least one of the contiguous planar outer surfaces.

2. The assembly according to claim 1, wherein the clamp is adjustable substantially along the length of the post.

3. The assembly according to claim 1, wherein the base comprises a post-attachment aperture and a bolt extending through the post-attachment aperture and coupled to a base aperture of the post.

4. The assembly according to claim 3, wherein the base further comprises a standoff section for allowing a head of the bolt to be disposed beneath the base and the base to lay flat upon an installation surface.

5. The assembly according to claim 1, wherein the base comprises an installation surface aperture and a bolt extending through the installation surface aperture and coupled to an installation surface.

6. The assembly according to claim 5, wherein the bolt comprises a lag bolt.

7. The assembly according to claim 1, wherein the tapered edge approaches the flat edge away from the post-receiving aperture.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) The preferred embodiments of the present invention are illustrated by way of example and not limited to the following figures:

(2) FIG. 1a shows a cross-sectional view of a snap-in channel nut in a first installation stage according to an exemplary embodiment.

(3) FIG. 1b shows a cross-sectional view of a snap-in channel nut in a second installation stage according to an exemplary embodiment.

(4) FIG. 1c shows a cross-sectional view of a snap-in channel nut in a third installation stage according to an exemplary embodiment.

(5) FIG. 1d shows a cross-sectional view of a snap-in channel nut in a fourth installation stage according to an exemplary embodiment.

(6) FIG. 1e shows a cross-sectional view of a snap-in channel nut in a first installation stage according to an exemplary embodiment.

(7) FIG. 1f shows a cross-sectional view of a snap-in channel nut in a second installation stage according to an exemplary embodiment.

(8) FIG. 1g shows a cross-sectional view of a snap-in channel nut in a third installation stage according to an exemplary embodiment.

(9) FIG. 1h shows a cross-sectional view of a snap-in channel nut in a fourth installation stage according to an exemplary embodiment.

(10) FIG. 2a shows an exploded perspective view of an L-foot and flashing assembly according to an exemplary embodiment.

(11) FIG. 2b shows an exploded cross-sectional view of an L-foot and flashing assembly according to an exemplary embodiment.

(12) FIG. 2c shows a cross-sectional view of an L-foot and flashing assembly according to an exemplary embodiment.

(13) FIG. 2d shows a perspective view of an L-foot and flashing assembly according to an exemplary embodiment.

(14) FIG. 2e shows a perspective view of a base according to an exemplary embodiment.

(15) FIG. 2f shows a perspective view of a flashing according to an exemplary embodiment.

(16) FIG. 3a shows a perspective view of a base according to an exemplary embodiment.

(17) FIG. 3b shows a perspective view of a flashing according to an exemplary embodiment.

(18) FIG. 3c shows a perspective view of a flashing according to an alternative exemplary embodiment.

(19) FIG. 3d shows a perspective view of a flashing system according to an exemplary embodiment.

(20) FIG. 4a shows an exploded perspective view of a post clamp according to an exemplary embodiment.

(21) FIG. 4b shows a perspective view of a post clamp according to an exemplary embodiment.

(22) FIG. 4c shows a perspective view of a post clamp according to an alternative exemplary embodiment.

(23) FIG. 4d shows a perspective view of a post clamp according to an alternative exemplary embodiment.

(24) FIG. 5a shows a cross sectional view of a clamp assembly according to an exemplary embodiment.

(25) FIG. 5b shows a cross sectional view of a clamp assembly according to an exemplary embodiment.

(26) FIG. 5c shows a cross sectional view of a clamp assembly according to an exemplary embodiment.

(27) FIG. 5d shows a cross sectional view of a clamp assembly according to an exemplary embodiment.

(28) FIG. 6a shows a cross sectional view of an L-foot assembly according to an exemplary embodiment.

(29) FIG. 6b shows a cross sectional view of an L-foot assembly according to an exemplary embodiment.

(30) FIG. 6c shows a cross sectional view of an L-foot assembly according to an exemplary embodiment.

(31) FIG. 6d shows a cross sectional view of an L-foot assembly according to an exemplary embodiment.

DETAILED DESCRIPTION

(32) Reference will now be made in detail to the preferred embodiments of the present invention, examples of which are illustrated in the accompanying drawings.

(33) Although the exemplary embodiments describe a solar module and solar module installation, the description herein is intended to include any component of a solar cell array to be secured, including, but not limited to, a photovoltaic array, a photovoltaic module, a solar cell, a rail, a solar panel, a solar tracker, a mounting post or pole, a mounting bracket, or other related hardware. However, the term module is not intended to be limited only to components used for solar energy and solar component installation. The module can apply to any component that can be secured to a roof or other surface, including, but not limited to, a satellite dish, an antenna, and HVAC equipment.

(34) Referring to FIGS. 1a to 1d, an exemplary embodiment showing a cross-sectional view of an installation of a snap-in channel nut 100, 110 is shown. Although this exemplary embodiment shows the installation of the snap-in channel nut 100, 110, the snap-in channel nut 100, 110 can be removed by using substantially the reverse method. Also, although two snap-in channel nuts 100, 110 are shown being installed into a rail 120, it is intended that an installation may utilize only one snap-in channel nut. In one example, only snap-in channel nut 110 is used because the rail 120 attaches to a module using means other than the snap-in channel nut 100. In another example, only snap-in channel nut 100 is used because the rail 120 is attached to a roof support using means other than the snap-in channel nut 110. Although the exemplary embodiment describes the installation and configuration of the snap-in channel nut 100 in substantially the same way as snap-in channel nut 110, each snap-in channel nut 100, 110 is not required to be identical to each other.

(35) The rail 120 can secure at least one module (not shown) and the rail 120 can be secured to a roof or other surface (not shown). As known by one of ordinary skill in the art, the rail 120 can be configured in different ways and is not limited to the configuration or orientation described in this exemplary embodiment. The rail 120 has a first component 120a and a second component 120b configured perpendicular to the first component 120a. At approximately the mid-point of the first component 120a, a third component 120c extends from the rail 120 in a direction substantially parallel to the second component 120a. A fourth component 120d extends in a substantially perpendicular direction from the third component 120c in a direction substantially parallel with the first component 120a. A fifth component 120e extends in a substantially perpendicular direction from the fourth component 120d in a direction substantially parallel with the second component 120b. A sixth component 120f extends in a substantially perpendicular direction from the fifth component 120e in a direction substantially parallel to the first component 120a.

(36) At a distal end of the first component 120a, a first flange 120g extends toward the center of the rail 120, thereby forming a recess 120h. In this exemplary embodiment, the rail 120 can have a greater thickness at a point before the recess 120h on the first component 120a. At a distal end of the second component 120b, a second flange 120i extends toward the center of the rail 120, thereby forming a recess 120j. In this exemplary embodiment, the rail 120 can have a greater thickness at a point before the recess 120j on the second component 120b. At a distal end of the sixth component 120f, a third flange 120k extends toward the center of the rail 120, thereby forming a recess 120l. In this exemplary embodiment, the rail 120 can have a greater thickness at a point before the recess 120l on the sixth component 120f. The third flange 120k opposes the first flange 120g. At substantially the intersection of the fifth component 120e and the sixth component 120f, a fourth flange 120m can extend to form a recess 120n. In this exemplary embodiment, the rail 120 can extend to on the opposing side of the recess 120n from the fourth flange 120m. The fourth flange 120m opposes the second flange 120i.

(37) In the exemplary embodiment shown, the distal ends of the first component 120a and the sixth component 120f can be used to support a module. The distal end of the second component 120b and the area near the intersection of the fifth component 120e and the sixth component 120f can be used to secure the rail 120 to a support member. One advantage to this configuration of rail 120 is that wires or cables can be run along a channel (e.g., between first component 120a and sixth component 120f) and the snap-in channel nut 100 can still be installed without interfering with the wires or cables.

(38) The rail 120 can be made of a conductive material, such as aluminum or stainless steel, or a non-conductive material, such as fiberglass, which can eliminate the need to ground the rail 120 when a solar cell module is attached.

(39) The snap-in channel nut 100 is shown as a cross-section, but is substantially rectangular. The nut 100 has an aperture configured to receive a threaded bolt 130. The nut 100 has a first flange 100a configured to engage recess 120h. The extension of the flange 100a causes a recess 100b. Recess 100b is configured to engage the first flange 120g of the rail 120. The nut 100 also has a second flange 100c configured to engage recess 120l. The extension of the flange 100c causes a recess 100d. The recess 100d is configured to engage the third flange 120k of the rail 120.

(40) The snap-in channel nut 110 is shown as a cross-section, but is substantially rectangular. The nut 110 has an aperture configured to receive a threaded bolt 140. The nut 110 has a first flange 110a configured to engage recess 120j. The extension of the flange 110a causes a recess 110b. Recess 110b is configured to engage the second flange 120i of the rail 120. The nut 110 also has a second flange 110c configured to engage recess 120n. The extension of the flange 110c causes a recess 110d. The recess 110d is configured to engage the fourth flange 120m of the rail 120. The nut 110 can secure a mounting component or support 150 to the rail 120.

(41) The nut 100, 110 and/or bolt 130, 140 can be composed of any known or convenient material, including, but not limited to metal, fiberglass, plastic, wood, composites or any other combination of materials. The nut 100, 110 can be manufactured by any process known in the art, including extrusion and cold-forging.

(42) As shown in FIG. 1a, the nut 100, 110 can be inserted into the rail by angling the nut 100, 110. Because of the flanges 100a, 100c, 110a, 110c, the nut 100, 110 cannot fit into the opening in the rail 120 without orienting the nut 100, 110 at an angle.

(43) As shown in FIG. 1b, the nut 100, 110 has been inserted into the rail 120 by orienting the nut 100, 110 at an angle. The depth of insertion of the nut 100, 110 may be limited by the placement of the head of the bolt 130, 140 or the support 150.

(44) As shown in FIG. 1c, the nut 100, 110 is oriented such that the bolt 130, 140 is more aligned with the direction of insertion. This orientation allows the nut 100, 110 to be inserted even further into the rail 120. The nut 100, 110 is inserted into the rail 120 until the flanges 100a, 100c, 110a, 110c are inserted past the flanges 120g, 120i, 120k, 120m.

(45) As shown in FIG. 1d, the nut 100, 110 can be secured by pulling the nut 100, 110 in a direction out of the rail 120 so that the flanges 100a, 100c, 110a, 110c engage recesses 120h, 120j, 120l, 120n. The configuration of the recesses 120h, 120j, 120l, 120n and the thicker rail portions before the recesses 120h, 120j, 120l, 120n can allow the nut 100, 110 to snap into the recesses 120h, 120j, 120l, 120n. The bolt 130, 140 can then be tightened to secure a module (not shown) or the support 150 to the rail 120. The nut 100, 110 can be removed in substantially the reverse method shown. This configuration can allow a user to more easily install and remove a module or support from a rail. Additionally, this configuration can allow a user to install and remove the module or support from a rail at any point along the rail without sliding the nut to or from the end of the rail.

(46) The nut 100, 110 can be installed in other rail configurations. For example, as shown in FIGS. 1e to 1h, the nut 100, 110 can be installed in a rail 121 configured for attachment to a ground mounting system (not shown) that has an existing substructure, including awnings and carports. The installation, removal, and adjustment of the nut 100, 110 in FIGS. 1e to 1h can be performed according to the method described with respect to FIGS. 1a to 1d.

(47) FIGS. 2a to 2d show a system 200 for securing a rail 210 to a composition roof 220. Although the rail 210 is shown in the exemplary embodiment, it is intended that this system 200 can be applied to secure any support member, module, or other component to the roof 220. Indeed, the support member can secure any number of rails or structural components, can be secured to a variety of roof types, can be installed on trellises and on motor vehicles, such as motorhomes.

(48) The roof 220 is generally made of a roof decking component 220a and a rafter component 220b. The roof 220 is typically oriented in a tilt, wherein a first end 220c of roof 220 is elevated higher than a second end 220d. The composition roof 220 can include a wood shake, shingle, and slate installation. Although the composition roof 220 is shown in a preferred embodiment, it is intended that the system 200 can be configured for other types of roofs, such as a concrete tile roof.

(49) The system 200 includes a base 230, a flashing 240, and an L-foot 250. As shown in FIG. 2e, The base 230 is shown as a rectangular component 230a (shown in FIG. 2e) having an aperture for receiving a lag bolt 230b. The lag bolt 230b, along with a washer 230d, can secure the base 230 to the roof 220. In this example, the lag bolt 230b is configured to screw into the rafter component 220b. A threaded stud 230c (shown in FIG. 2e) extends upwards from the base 230 for securing the L-foot 250. The base 230 can be sealed to the roof 220.

(50) The flashing 240 is positioned over the base 230. The flashing 240 is shown as a substantially flat rectangular component 240a (shown in FIG. 2d) having a dome 240b (shown in FIG. 2d) configured to cover the base 230, which protrudes from the surface of the roof 220. The dome 240b can be made of may be any weather resistant material known and/convenient, such as plastic, rubber, or metal. The flashing 240a and the dome 240b are formed, for example by stamping, the flashing 240 from a single piece of sheetmetal such that the flashing 240a and the dome 240b are integrally coupled. The flashing 240 also has an aperture 240c (shown in FIG. 2f) for receiving the threaded stud 230c. The flashing 240 provides a watertight seal around the base 230. The flashing 240 extends a distance toward the first end 220c of roof 220 so that a shingle 220e of the roof can overlap the flashing 240, as shown in FIG. 2f. The flashing 240 can be made of galvanized steel or other material known to one of ordinary skill in the art.

(51) The L-foot 250 acts as a support having an L-foot base 250a that is secured to the threaded stud 230c through an aperture 250b using a flange nut 260. An L-foot extension 250c extends from the L-foot base 250a at about 90 degrees. The L-foot extension 250c has an elongated aperture 250d for securing the L-foot 250 to the rail 210, shown in the exemplary embodiment with a channel nut 270. The elongated shape of aperture 250d can allow for fine-tuned height adjustments. A bolt 280 and a washer 290 can be used to secure the L-foot 250 to the channel nut 270.

(52) As shown in FIGS. 3a to 3d, an alternative system is shown with full flashing. In this exemplary embodiment, a base 330a is secured to a roof 320 by a bolt 330b. A post 330b attached by a bolt (similarly shown as bolt 415 in FIG. 4a) extending from the base 330a extends away from the roof 320. A flashing 340 can be installed over the base 330a and substantially over the post 330b as shown in FIG. 3b. The flashing has a substantially flat rectangular component 340a and a post flashing component 340b that substantially covers the base 330a and the post 330b. The post flashing component 340b can be substantially cone-shaped. In an alternative embodiment shown in FIG. 3c, a rectangular component 340c can mimic the undulating shape of the roof 320 to allow for better protection of the base 330a. Once the flashing 340 has been installed, the post 330b can be secured to a rail 310 or other component using a clamp 350 or other securing mechanism.

(53) An adjustable clamp assembly can be used to adjust the height of a rail or module secured to a roof or other surface. Referring to FIGS. 4a and 4b, an assembled post clamp 400 is shown. The post clamp 400 can be used with all roof types. As shown in FIGS. 4a and 4b, a post is used. Alternatively, in FIGS. 6a to 6d, an adjustable L-foot assembly is mounted to a roof.

(54) The post clamp 400 includes a standoff base 410, a post 420, and a clamp 430. The standoff base 410 can be secured to a roof or other surface using a lag bolt 405 and a washer (not shown). Alternatively, the standoff base 410 can be secured using nails, epoxy, or other known methods. The standoff base 410 can be made of a durable weather resistant material, such as aluminum or stainless steel. A bolt 415 and a lock washer 425 can secure the post 420 to the standoff base 410. The post 430, as shown in this exemplary embodiment, is a cylindrical member, but can have any polygonal shape, including rectangular or hexagonal. The post 430 can be composed of any rigid weather resistant material, such as aluminum, steel, fiberglass, or any other material known and/or convenient. The post 430 can have apertures at each end for attachment to the standoff base 410 or other component.

(55) The clamp 430 can be removably attached to the post 420 to enable a height adjustment of a module or rail, as well as easy installation and removal of the clamp 430 from the post 420. The clamp 430 has an aperture 430a for receiving the post 420. The clamp 430 also has a first flange 430b and an opposing second flange 430c which are separated by a void that abuts the aperture 430a. The first and second flanges 430b, 430c taper away from the aperture 430a. The clamp 430 has an aperture 430d for receiving a bolt 435 thread through a washer 440. The bolt 435 extends through the first flange 430b and the second flange 430c to a module or rail, shown here as a channel nut 445 used to secure a rail 450. The bolt 435 can also secure the clamp 430 to an L-foot 455, module, rail, or other component, as shown in a steep tilt configuration depicted in FIG. 4c. As the bolt 435 is actuated and enters the aperture 430d, the first flange 430b and the second flange 430c move toward each other to tighten the clamp 430 on the post 420. The clamp 430 can remain in position on the post 420 because of the pressure exerted by the tightened clamp 430 and the resulting friction that must be overcome to move the clamp 430. In order to loosen the clamp 430 for adjustment or removal, the bolt 435 is rotated in a direction to disengage the aperture 430d. The clamp 430, which is attached to the rail 450, can be adjusted along post 420 to adjust the height of the rail 450. As shown in a shallow tilt configuration depicted in FIG. 4d, in order to tilt a module 460, clamp 430 on a first post 420a can be positioned higher than a clamp 430 on a second post 420b.

(56) A clamp can adjust along a post at any varied height. If the post is not high enough, the post can be extended using at least one spacer. Referring to FIGS. 5a and 5b, a post 500 is secured to a standoff base 510 using a bolt 520. A clamp 530 secures a rail 540 to the post 500. As shown in FIG. 5a, the clamp 530 is at a first position (shown having a rail height at about 7.5 inches) along the post 500. As shown in FIG. 5b, the clamp 530 is at a second position (shown having a rail height at about 8.5 inches) along the post 500. The clamp 530 can be tightened at any point along the post 500 and is not limited to those positions shown in these exemplary embodiments.

(57) At least one spacer can be added to the post to allow a further height adjustment and/or leveling on an uneven surface. As shown in FIG. 5c, one spacer 550 has been added to the top of the post 500. As a result, the clamp 530 can be adjusted to achieve a third position (shown having a rail height at about 9.5 inches) that, upon adding the spacer 550, can be adjusted from about 7.5 inches to about 9.5 inches. As shown in FIG. 5d, two spacers 550 have been added to the top of the post 500. As a result, the clamp 530 can be adjusted to achieve a fourth position (shown having a rail height at about 10.5 inches) that, upon adding the second spacer 550, can be adjusted from about 7.5 inches to about 10.5 inches. The spacer 550 acts as an extension of the post 500 and can take a similar form. For example, if the post 500 is a cylindrical member, the spacer 500 can also be a cylindrical member having the same diameter. The spacer 550 can attach to the post 500 or another spacer 550 using a set screw (not shown). The spacer 550 can be manufactured in a standard size, such as one inch, for easier calculations of height adjustments. The clamp 530 can be tightened at any point along the post 500 and is not limited to those positions shown in these exemplary embodiments.

(58) A spacer can also be added to an L-foot support for added height and/or leveling on an uneven surface. FIG. 6a shows an L-foot 600 securing a rail 640 to a roof (not shown), wherein the L-foot 600 is attached to a base 610 and a flashing 620. The rail 640 is positioned with a rail height of about 3.33 inches.

(59) Referring to FIG. 6b, the rail 640 can be adjusted along the L-foot 600 using an elongated aperture (shown as aperture 250d in FIG. 2a) in L-foot 600. The rail 640 can be positioned with a rail height of between about 3.33 and 4.33 inches.

(60) Referring to FIG. 6c, a spacer 650 can be secured to the base 610 by a threaded stud 660 extending from the base 610. A set screw 670 can secure the L-foot 600 to the spacer 650. A nut 680 secures the L-foot 600 to the set screw 670. The rail 640 can be positioned with a rail height of between about 4.33 and 5.33 inches.

(61) Referring to FIG. 6d, a first spacer 650a can be secured to the base 610 by threaded stud 660. A second spacer 650b can be secured to the first spacer 650a and L-foot 600 can be secured to the second spacer 650b by set screw 660. Nut 680 secures the L-foot 600 to the set screw 670. Additional spacers can also be included between first spacer 650a and second spacer 650b. The rail 640 can be positioned with a rail height of between about 5.33 inches and 6.33 inches.

(62) The embodiments described above are intended to be exemplary. One skilled in the art recognizes that numerous alternative components and embodiments that may be substituted for the particular examples described herein and still fall within the scope of the invention.