Abstract: A u-shaped splice that is used to connect two solar mounting rails, includes barbs that interact with the rails, requiring more force to remove the splice from the rails than the force required to insert the splice into the rails. Wedges, located at a mid-point between ends of the splice interact with the rails, creating an interference fit between the splice and the rails.

Abstract: A threaded fastener for securing a plate to a layered substrate is provided, as well as methods for installing the threaded fastener. An exemplary threaded fastener may include a head, and a shank having a longitudinal axis between a first end and a second end. The shank may be connected to the head at the second end. The shank may have a pointed terminus at the first end. The shank may have a first portion between the first end and a transition region. The first portion may include a first thread having a first thread profile that encircles the first portion. The shank may have a second portion between the transition region and the second end. The transition region may reside between the first portion and the second portion. The second portion may include a second thread having a second thread profile that encircles the second portion.

Abstract: Apparatuses for clamping rails and methods for rail installation are provided. A clamp apparatus may include a first grip body that includes a first groove and a second grip body that includes a second groove. Alignment of the first groove and the second groove may form a groove pair configured to couple to one or more flanges of a rail. The clamp apparatus may further include a fastener, as well as a flange spring that extends from the first grip body and that flexibly engages with the second grip body. Flexing the flange spring may allow the first grip body to move away from the second grip body along a length of the fastener.

Abstract: A twist-lock clamp to attach a solar module to a rail system includes a spring between a top clamp and a t-nut, with features on the spring and top clamp to restrict rotation relative to each other. The t-nut includes features allowing rotation of about 90 degrees when the t-nut is inserted in a rail, but restrict rotation beyond about 90 degrees. The spring serves to hold the top clamp and t-nut apart while allowing the twist-lock clamp to resist sliding in the rail during installation.

Abstract: Systems for grounding junction box are provided, as well as methods for installing the systems. An exemplary grounding junction box may include a housing, a grounding bar affixed to the housing and including a first end and a second end, at least one ground lug mounted within the enclosure of the housing, and a rail lock mounted to the second end of the grounding bar. The housing comprises a base wall, at least one side wall extending from the base wall, and a lid attached to the at least one side wall, forming an enclosure when closed. The at least one ground lug electrically connects the grounding bar and includes a wire guide receiving and securing a grounding wire with a ground lug fastener. The rail lock is configured to secure the grounding bar to a rail and form an electrical bond path from the grounding wire to the rail.

Abstract: A twist-lock clamp to attach a solar module to a rail system includes a spring between a top clamp and a t-nut, with features on the spring and top clamp to restrict rotation relative to each other. The t-nut includes features allowing rotation of about 90 degrees when the t-nut is inserted in a rail, but restrict rotation beyond about 90 degrees. The spring serves to hold the top clamp and t-nut apart while allowing the twist-lock clamp to resist sliding in the rail during installation.

Abstract: Apparatuses for clamping rails and methods for rail installation are provided. A clamp apparatus may include a first grip body that includes a first groove and a second grip body that includes a second groove. Alignment of the first groove and the second groove may form a groove pair configured to couple to one or more flanges of a rail. The clamp apparatus may further include a fastener, as well as a flange spring that extends from the first grip body and that flexibly engages with the second grip body. Flexing the flange spring may allow the first grip body to move away from the second grip body along a length of the fastener.

Abstract: A multi-rail system for mounting solar modules to a surface, such as a roof, uses two rails to support a first row of solar modules, and a single rail to support each subsequent row of solar modules. Splices connect edges of solar modules between rows, providing support along one edge of the solar modules for the subsequent rows.

Abstract: A system and a method of securing and sealing a roof attachment to a roof surface is disclosed. A roof attachment may include a base, a protective covering, volume of sealant, and a release mechanism. The release mechanism includes one or more release slides. The release slides may have one or more mechanism apertures to receive a fastener. The release slide may have one or more flexible tabs that cooperate with one or more indentation or flanges or grooves in base to substantially retain the release slide.

Abstract: Systems and methods for mounting solar modules are disclosed herein. A mounting system for solar modules includes a first-row solar module and a second-row solar module having a bottom edge and a top edge opposite the bottom edge, a structural clamp configured to connect the top edge of the first-row solar module to a bottom edge of a second-row solar module, roof attachments configured to secure the first-row solar module and the second-row solar module, and structural clamps that connect the first-row solar module to the second-row solar module. The mounting system for solar modules may be installed by installing a first row of roof attachments to a roof surface using fasteners, installing a second row of roof attachments to a roof surface using fasteners, and installing a third row of roof attachments to a roof surface using fasteners.

Abstract: A splice having a main body and one or more protrusions extending from the main body. The one or more protrusions can be operable to interfere with a rail when the main body is installed into an opening of the rail. The one or more protrusions may be operable to cut into a coating of the rail and form an electrical connection between the rail and the main body.

Abstract: A splice having a main body and one or more protrusions extending from the main body. The one or more protrusions can be operable to interfere with a rail when the main body is installed into an opening of the rail. The one or more protrusions may be operable to cut into a coating of the rail and form an electrical connection between the rail and the main body.

Abstract: A capsule for delivering sealant for fastener is disclosed. A capsule includes a cavity that contains an amount of sealant, a perimeter wall and a top cap that define the cavity, where the top cap is configured align with an interior contour of the perimeter wall and collapse through the perimeter wall; and one or more breakaway tabs disposed on the perimeter wall, wherein the breakaway tabs are configured to resist a release of sealant within the cavity.

Abstract: A system to support solar energy modules is described. The system includes an upper tilt leg assembly and a lower tilt leg assembly. The upper tilt leg assembly includes an upper horizontal rail, a support leg, and an upper tilt bracket assembly. The upper bracket assembly may include a lower body pivotally connected to the support leg and an upper body pivotally connected to the upper horizontal rail. The lower body of the tilt bracket may include one or more fasteners and one or more flanges that protrude into the cross-section of the support leg. A method of installing supports for solar energy modules is described. The method includes installing one or more roof attachments onto an installation surface, attaching one or more leg supports to the roof attachments and tilt brackets, and attaching horizontal rails to roof attachments and the tilt brackets.

Abstract: A multi-rail system for mounting solar modules to a surface, such as a roof, uses two rails to support a first row of solar modules, and a single rail to support each subsequent row of solar modules. Splices connect edges of solar modules between rows, providing support along one edge of the solar modules for the subsequent rows.

Abstract: A u-shaped clamp that includes offset bends at distal ends, accepts a threaded fastener through two apertures, where tightening the fastener brings two flanges of the u-shaped clamp together to grip a wire, a cable or a pipe. An offset bend on one end of one flange serves to hold a wire or cable in position until the fastener is tightened.

Abstract: A coupling clamp is provided that includes a top clamp and a bottom clamp. The top clamp may include a top vertical flange and a top lateral flange. The bottom clamp may include a bottom vertical flange and one or more bottom lateral flanges that extend laterally in opposite directions. At least one of the bottom lateral flanges may include a first portion having a surface configured to engage with a solar module and a second portion connected to the bottom vertical flange at an intersection below the surface of the first portion. The coupling clamp may be installed onto one or more solar modules that are positioned onto a rail that has an installed rail clamp. Another solar module may be positioned on the coupling clamp and rail and then slid under the rail clamp, which may be tightened to secure the other solar module to the rail.

Abstract: Apparatuses for roof attachment are provided, as well as methods for assembling and installing roof attachment apparatuses. An exemplary roof attachment apparatus may include a mount and a fastener configured to engage with an installation surface. The fastener may be configured to attach the mount to the installation surface when engaged with the installation surface. The roof attachment apparatus may further include a compressible sealant disposed between a bottom of the mount and the installation surface when the mount is attached to the installation surface. The sealant may thus be compressed based on the engagement between the fastener and the installation surface, and the compressed sealant may flow to fill a volume of space between the bottom of the mount and the installation surface.

Abstract: A multi-rail system for mounting solar modules to a surface, such as a roof, uses two rails to support a first row of solar modules, and a single rail to support each subsequent row of solar modules. Splices connect edges of solar modules between rows, providing support along one edge of the solar modules for the subsequent rows.