CROSS REFERENCE TO RELATED APPLICATION

[0001] The present application claims the benefits of and priority, under 35 U.S.C. § 119(e), to U.S. Provisional Application Serial No. 61/460,949, filed January 10, 2011, entitled "APPARATUSAND METHOD FOR FRAME CRIMPING," which is incorporated herein by this reference in its entirety for all that it teaches and for all purposes.

BACKGROUND

[0002] Frame rail structures are commonly used to facilitate the mounting of flat panel objects. For example, in many photovoltaic (PV) solar modules, solar panels are supported by frame rail structures that include an assembly of four frame rails and four reshaped keys. FIG. 1 shows a typical frame rail assembly of a solar module. Each of frame rails supports a respective peripheral edge of the panel. Typically, the frame rail is extruded aluminum stock with a uniform cross-sectional geometry projected along its entire length. The cross-section geometry defines an interior channel that is exposed at each end of the frame rail. During assembly, the four frame rails are arranged end-to-end in a closed rectangular fashion. As shown in FIG. 2, each corner includes two adjacent frame rails perpendicularly coupled to one another via one L-shaped key. The L-shaped key is essentially a plate structure angled at 90 degrees such that one of its sides can be inserted into the channel of one frame rail and the other can be inserted into the channel of the adjacent frame rail. After each side of the L-shaped key is inserted into a respective channel, it is fixed in place by some suitable means moved over each corner to squeeze the frame channel and lock the corners together. Currently, there are fully automated machines that can simultaneously crimp all four corners at once on a production floor.

[0003] Although current clinching machines are suitable for some manufacturing applications, they also have several disadvantages. For example, such machines include many complex and heavy duty components (e.g., electronic control boxes, large hydraulic cylinder pumps, etc.). Consequently, such machines are expensive in terms of both their high initial costs and their high operating costs (i.e. power costs, maintenance costs). Furthermore, such machines are relatively large and, therefore, occupy significant manufacturing floor space. Such machines are also not portable and not very flexible to facilitate work on a wide variety of frame designs, because they are typically only intended for manufacturing high numbers of identical frames. As a result of this low versatility and flexibility, conventional machines are not typically suitable for constructing prototype frames. What is needed therefore is a crimping device that is less expensive, more portable, and more versatile.

SUMMARY

[0004] Described are embodiments of a portable, handheld crimping device that can be used to connect rails to create frames of varying designs for use to hold items such as photovoltaic panels. The embodiments described below are provided only for illustrative purposes and other embodiments may include fewer features, or more features, than those described.

[0005] One embodiment is directed to a portable device for creating indentations in at least one rail, the portable device includes a rod, wherein a first end of the rod is movable from a first position to a second position, a head connected to the first end of the rod, and at least one stud connected to the head, wherein when the first end of the rod is moved to the second position, the at least one stud engages the at least one rail creating indentations on the at least one rail.

[0006] Another embodiment is directed to a portable handheld device for connecting two metal rails together, the portable handheld device includes a hydraulic cylinder that has a rod. The first end of the rod is movable from a first position to a second position. A head is connected to the first end of the rod. At least one stud is connected to the head and when the hydraulic cylinder is activated, the first end of the rod is moved to the second position and the at least one stud engages a first rail.

[0007] Yet another embodiment is directed to a method for connecting two rails together, the method includes positioning a first rail and a second rail using an angle. A first end of an L-shaped key is then positioned in a first channel of the first rail, and a second end of the L-shaped key is positioned in a second channel of the second rail. The L-shaped key is then secured in the first channel and in the second channel using a portable crimping device. The portable crimping device includes a hydraulic cylinder comprising a rod, wherein a first end of the rod is movable from a first position to a second position, and a head connected to the first end of the rod. At least one stud is connected to the head and when the hydraulic cylinder is activated, the first end of the rod is moved to the second position and the at least one stud engages and deforms a portion of the first rail.

[0008] The present disclosure can provide a number of advantages depending on the particular aspect, embodiment, and/or configuration. [0009] The phrases "at least one", "one or more", and "and/or" are open-ended expressions that are both conjunctive and disjunctive in operation. For example, each of the expressions "at least one of A, B and C", "at least one of A, B, or C", "one or more of A, B, and C", "one or more of A, B, or C" and "A, B, and/or C" means A alone, B alone, C alone, A and B together, A and C together, B and C together, or A, B and C together.

[0010] The term "a" or "an" entity refers to one or more of that entity. As such, the terms "a" (or "an"), "one or more" and "at least one" can be used interchangeably herein. It is also to be noted that the terms "comprising", "including", and "having" can be used interchangeably.

[0011] The term "automatic" and variations thereof, as used herein, refers to any process or operation done without material human input when the process or operation is performed. However, a process or operation can be automatic, even though performance of the process or operation uses material or immaterial human input, if the input is received before performance of the process or operation. Human input is deemed to be material if such input influences how the process or operation will be performed. Human input that consents to the performance of the process or operation is not deemed to be "material".

[0012] The term "portable" as used herein means capable of being easily carried or moved from one location to another.

[0013] The term "handheld" as used herein means cable of being operated while being held in a user's hand or hands.

[0014] It shall be understood that the term "means" as used herein shall be given its broadest possible interpretation in accordance with 35 U.S.C., Section 1 12, Paragraph 6. Accordingly, a claim incorporating the term "means" shall cover all structures, materials, or acts set forth herein, and all of the equivalents thereof. Further, the structures, materials or acts and the equivalents thereof shall include all those described in the summary of the invention, brief description of the drawings, detailed description, abstract, and claims themselves.

[0015] The preceding is a simplified summary of the disclosure to provide an understanding of some aspects of the disclosure. This summary is neither an extensive nor exhaustive overview of the disclosure and its various aspects, embodiments, and/or configurations. It is intended neither to identify key or critical elements of the disclosure nor to delineate the scope of the disclosure but to present selected concepts of the disclosure in a simplified form as an introduction to the more detailed description presented below. As will be appreciated, other aspects, embodiments, and/or

configurations of the disclosure are possible utilizing, alone or in combination, one or more of the features set forth above or described in detail below.

BRIEF DESCRIPTION OF THE DRAWINGS

[0016] FIG. 1 illustrates an exploded view of a frame that is typically used to hold a photovoltaic panel;

[0017] FIG. 2 illustrates a close-up view of one of the corners of the frame illustrated in FIG. 2;

[0018] FIG. 3A and 3B illustrates a side view of one basic embodiment of a portable crimping device;

[0019] FIG. 4A and 4B illustrate a top perspective view and a bottom perspective view of another embodiment of a portable and handheld crimping device;

[0020] FIG. 5 illustrates a portable and handheld crimping device connected to a manual hydraulic pump used to activate the hydraulic cylinder of the portable and handheld crimping device;

[0021] FIG. 6 illustrates the portable and handheld crimping device shown in FIGS. 4A and 4B when the hydraulic cylinder has been activated to move the rod to a second position;

[0022] FIG. 7 illustrates the corner of a frame after it has been crimped using an embodiment;

[0023] FIG. 8 illustrates a close-up view of the corner shown in FIG. 7;

[0024] FIG. 10 illustrates a top perspective view of the corner shown in FIG. 7.

[0025] FIG. 10 illustrates a flow chart of an embodiment for a method of joining two rails for creating a frame assembly.

[0026] In the appended figures, similar, but not necessarily the same, components and/or features may have the same reference label. Further, various components of the same type may be distinguished by following the reference label by a letter that distinguishes among the similar components. If only the first reference label is used in the specification, the description is applicable to any one of the similar components having the same first reference label irrespective of the second reference label.

DETAILED DESCRIPTION

[0027] Presented herein are embodiments of a device. The device is in embodiments a crimping device that is portable, and in some embodiments, handheld so that it can be easily moved from one location to another including to on-site locations where either brand new or previously used frames are being repaired or replaced. The device can include a rod that is movable from a first position to a second position. A head is connected to the rod, and a stud is connected to the head. When the rod is moved from the first position to the second position the stud engages a rail of a frame and deforms a portion of the rail, which secures an L-shaped key, e.g., bracket in a channel of the rail. A second rail can then be secured to a second side of the L-shaped key to create a corner of a frame. The process can be repeated to generate an enclosed frame for holding items such as Flat Plate Photovoltaic Laminates or Glass.

[0028] Embodiments of the present invention overcome some of the problems associated with the prior art, by providing a portable frame rail corner crimping device that facilitates crimping the corners of frames of varying design. FIG. 1 illustrates an exploded view of one frame 100 that can be used to hold items such as a photovoltaic panel 112. As illustrated in FIG. 1, frame 100 includes rails 104A-D and brackets, shown as L-shaped keys 108A-D, for connecting the rails together to form frame 100.

[0029] FIG. 2 illustrates a close up, exploded view of one corner of frame 100. Rail 104A includes a channel into which one side of L-shaped key 108A is positioned. Rail 104B also includes a channel into which a second side of L-shaped key 108A is positioned. As described in greater detail below, the L-shaped key 108A is secured within the channels of rails 104A and 104B by a portable crimping device that engages and deforms a portion of rails 104A and 104B securing the L-shaped key in the rails.

[0030] FIG. 3 illustrates a side view of a portable device 300 that is a basic embodiment of the present invention and is used to create frame assemblies as shown and described with respect to FIGS. 1 and 2. Device 300 includes a hydraulic cylinder 304 that includes a rod 308. Hydraulic cylinder 304 is secured to a base of device 300 using brackets 306A and 306B. In other embodiments, hydraulic cylinder 304 is secured using other structures, such as a cage structure. As can be appreciated, the hydraulic cylinder 304 can be a oneway or two-way hydraulic cylinder. When the hydraulic cylinder 304 is activated, the rod 308 is moved into and out of hydraulic cylinder 304, which causes end 312 of rod 308 to move from a first position 336 to a second position 340. A number of conduits 31 OA and 310B, e.g. pipes, can be used to deliver and/or remove hydraulic fluid to and from hydraulic cylinder 304. In some embodiments, conduits 310A and 310B, can also serve as a handle for device 300.

[0031] Connected to end 312 is a head 320, which can also be referred to as a crimping head, which includes a stud 324. The head 320 can be connected to end 312 by any suitable means. In embodiments, this may include rods, shafts, gears, brackets, blocks, fasteners (screws, bolts, nuts, washers), welds, soldering joints, adhesives, or other means. In FIG. 3A and 3B a connection 322 between head 320 and end 312 includes at least a connecting block 316 and one or more additional blocks, brackets and/or fasteners.

[0032] Additionally, a spring 344 is connected to the block 316. Spring 344 applies a force to end 312 to assist in moving end 312 back to the first position 336 after it has moved to the second position 340. Spring 344 is useful in those situations in which hydraulic cylinder 304 is a single acting hydraulic cylinder and needs a force to move end 312 back to the first position 336. In other embodiments when the hydraulic cylinder is a dual acting hydraulic cylinder, the springs are merely used to assist in moving the end 312 back to the first position.

[0033] FIG. 3B illustrates that when end 312 is moved from the first position 336 to the second position 340, the stud 324 engages a rail 348 positioned in front of the stud 324 using an angle 332, which is used to position rail 348. The stud 320 creates a concentrated force when it engages the rail 348 deforming at least a portion of the rail 348 and creating an indentation 352 in the rail 348. As described in greater detail below, the deformation of the rail 348 is used in embodiments to secure an L-shaped key in a channel of the rail 348, which is used in creating a frame.

[0034] FIG. 4 shows a perspective view of another embodiment of a portable and handheld device 300. The device 300 includes a hydraulic cylinder 304, which when implemented as a double acting cylinder is operative to drive the crimping head 320 in either a pushing mode or a pulling mode. During the crimping of a frame, the hydraulic cylinder 304 operates in the pulling mode wherein the hydraulic pressure causes the rod 308 to retract into the cylinder 304 (see e.g., FIG. 6). The device 300 also includes two springs 344A and 344B that return the crimping head back to its first position when it is not being pulled by the cylinder 304. As shown in FIG. 4, the device 300 is in an open position because it is disconnected from a hydraulic pressure source.

[0035] FIG. 4B shows a perspective view of the bottom of the embodiment of device 300 shown in FIG. 4A. As shown, the apparatus includes an angle 332 that may include a padded region. Angle 332 is adapted to cradle a ninety degree frame corner by allowing a first rail and a second rail to be positioned. The head 320 shown in FIG. 4B is positioned within the interior of angle 332 and includes two studs 324A and 324B. When the head 320 is moved along a linear path, e.g., when the cylinder 304 is actuated in the pulling mode, the head will approach the two rails from and approximately 45 degree angle. Further, the two studs 324A and 324B impart a concentrated force on each respective frame rail. The force imparted on each is sufficient to deform the rails. A different side of an L-shaped key is compressed within the rails. Deforming the rails simultaneously locks both frame rails onto the same L-shaped key (not shown). In addition, the angled orientation of the studs with respect to the frame rails causes the frame rails to be compressed together during the crimping process.

[0036] The degree of deformation required to secure a frame rail to a bracket, or key, will depend on the particular application. Some applications may only require a minor indentation while others may require more severe deformations such as, for example, piercing completely through a frame rail and the key seated therein.

[0037] Although specific features of the angle 332 are shown in FIG. 4B the present the invention is not limited thereto. For example, angle 332 is shown as a 90° angle, however in some embodiments angle 332 may be more or less than 90°. Angle 332 may be made using two sidewalls that meet, however in other embodiments the angle 332 may be made by a single wall or by some other means. In other embodiments, angle 332 may not include an actual angle but will include two side walls that allow two rails to be positioned at a predetermined angle, with the sidewalls never actually meeting. These and other variations are possible for positioning two rails at a predetermined angle to each together, all of which are within the scope of the present invention.

[0038] It is also noted that although device 300 is shown in FIGS. 4 A and 4B with two studs, other embodiments may include one, two, or more than two studs. In one specific embodiment, there may be four studs connected to head 320 to create two indentations on each rail of a corner. The studs on head 320 can also be positioned in any way to create any desired indentation pattern on the rails of a corner.

[0039] Also, the studs in FIGS. 4A and 4B are shown as generally conical in shape; however the present invention is not limited thereto. In other embodiments, the studs may have square, spherical, cylindrical, hexagonal, pentagonal, or any other shape. In some embodiments, the tips of the studs can be selected depending on the material used in the rails, e.g., metal alloys, plastics, or composites. For example, for more ductile material, the tips may be blunt, such as a flat tip or a rounded tip (e.g. bullet nose), while for harder materials the tips may be sharper or more pointed, such as conical or shaped like a pyramid. Accordingly, the particular shape of the studs can be selected for indenting the specific material used to make the rails. In embodiments, the studs are easily replaceable so that they can be interchanged. As one example, the studs may have tread that corresponds to tread in head 320. Other mechanisms for making the studs interchangeable are also within the scope of the present invention.

[0040] FIG. 5 shows an embodiment of device 300 coupled to a hydraulic hand pump 500. Device 300 of FIG. 5 is portable and handheld, and can be manually operated. This enables crimping operations to be performed wherever needed. For example, device 300 could be used to perform brand new corner crimps on new parts or onsite repairs, thus eliminating the need to disassemble frame parts and bring them to a stationary machine. Although in FIG. 5 device 300 is driven by a manual hydraulic pump, other forms of manual and/or automatic driving means could also be implemented. For example, automatic or manual pneumatic systems, scissor systems, and/or any type of driving means could be used to achieve mechanical advantage and/or automatic power. In addition to being portable and handheld, device 300 is also extremely versatile because many features are adjustable and/or interchangeable so as to accommodate for different applications and/or desirable outcomes. For example, the tooling of the apparatus can be changed in a relatively short period of time. Furthermore, the sizes, shapes, and/or configurations of the tooling can be changed so as to achieve various different crimp patterns. The overall portability and versatility of the apparatus make it particularly useful for constructing prototype frames. In addition, the apparatus can be used to crimp the corners of frames of various lengths and widths.

[0041] FIG. 6 illustrates device 300 shown in FIGS. 4A and 4B in a closed position as used to crimp a corner of a frame rail assembly. As shown, the apparatus is in an actuated state such that the rod 308 is retracted into the cylinder and the return springs 344A and 344B are stretched.

[0042] FIG. 7 illustrates an embodiment of device 300 with a corner of a frame rail assembly after being crimped by device 300. The corner is formed by rail 104A and 104B and an L-shaped key not shown but positioned within channels of the rails 104A and 104B. As shown, each frame rail includes an indentation, indentation 704 on rail 104A and indentation 708 on rail 104B. Indentation 704 is formed by stud 324A and 708 is formed by stud 324B, FIG. 8 illustrates a close up of the corner shown in FIG. 7.

[0043] FIG. 9 illustrates the exterior of the frame rail assembly 900 after being crimped by the embodiment of device 300 shown in FIGS. 4A and 4B. It is worth noting that no deformation has occurred on the exterior surface of the frame rails.

[0100] Referring now to FIG. 10, a flow diagram 1000 in accordance with at least some embodiments of the present disclosure is shown and will be described. Flow 1000 is in embodiments performed to create frame assemblies for use in holding various items including photovoltaic panels, screens, windows, art work, and other items that utilize a frame.

[0101] Flow 1000 starts at 1004. Flow 1000 passes from 1004 to step 1008 where one or more rails are positioned using an angle such as angle 332 illustrated above. The angle does not have to include walls that meet at an angle (or a single wall with an angle);

although in some embodiments the angle will have one or more sidewalls that meet to form a predetermined angle. In other embodiments the angle may merely be two sidewalls that allow one rail to be positioned at a predetermined angle with respect to a second rail.

[0102] Once the rail(s) has been positioned at step 1004, a bracket, such as an L-shaped key, is positioned at step 1008 within a channel of the rail or rails positioned at step 1004. In embodiments, after step 1008, step 1004 may be repeated to position a second rail with respect to the first rail. In these embodiments, step 1008 will also be performed again to position another side of the bracket within a channel of the second rail. After step 1008, the bracket is secured within the rail or rails at step 1012.

[0103] Step 1012 involves use of a portable device, which may be handheld, that includes, in embodiments, a hydraulic cylinder with a rod. One end of the rod is moved from a first position to a second position when the hydraulic cylinder is activated. A head is connected to the end of the rod, and a stud is connected to the head. When the end of the rod is moved from the first position to the second position, the stud engages and deforms a portion of at least one of the rails positioned at step 1004. The deformation of the rail secures the bracket within the channel of the rail. Step 1012 may be performed a number of times, or in some embodiments it is just performed once and creates multiple indentations that secures the bracket within more than one rail. The steps of flow 1000 can be repeated to create an enclosed frame assembly that hold an item. Flow 1000 ends at 1020.

[0104] The exemplary systems and methods of this disclosure have been described in relation to FIGS 1-10. However, to avoid unnecessarily obscuring the present disclosure, the preceding description omits a number of loiown structures and devices. This omission is not to be construed as a limitation of the scopes of the claims. Specific details are set forth to provide an understanding of the present disclosure. It should however be appreciated that the present disclosure may be practiced in a variety of ways beyond the specific detail set forth herein. [0105] Also, while the flowcharts have been discussed and illustrated in relation to a particular sequence of events, it should be appreciated that changes, additions, and omissions to this sequence can occur without materially affecting the operation of the disclosed embodiments, configuration, and aspects.

[0106] A number of variations and modifications of the disclosure can be used. It would be possible to provide for some features of the disclosure without providing others. For example in one alternative embodiment, the head 320 of device 300 shown in FIGS. 3A and 3B may be more directly connected to end 312 instead of through connection 322.

[0107] The present disclosure, in various aspects, embodiments, and/or configurations, includes components, methods, processes, systems and/or apparatus substantially as depicted and described herein, including various aspects, embodiments, configurations embodiments, subcombinations, and/or subsets thereof. Those of skill in the art will understand how to make and use the disclosed aspects, embodiments, and/or

configurations after understanding the present disclosure. The present disclosure, in various aspects, embodiments, and/or configurations, includes providing devices and processes in the absence of items not depicted and/or described herein or in various aspects, embodiments, and/or configurations hereof, including in the absence of such items as may have been used in previous devices or processes, e.g., for improving performance, achieving ease and\or reducing cost of implementation,

[0108] The foregoing discussion has been presented for purposes of illustration and description. The foregoing is not intended to limit the disclosure to the form or forms disclosed herein. In the foregoing Detailed Description for example, various features of the disclosure are grouped together in one or more aspects, embodiments, and/or configurations for the purpose of streamlining the disclosure. The features of the aspects, embodiments, and/or configurations of the disclosure may be combined in alternate aspects, embodiments, and/or configurations other than those discussed above. This method of disclosure is not to be interpreted as reflecting an intention that the claims require more features than are expressly recited in each claim. Rather, as the following claims reflect, inventive aspects lie in less than all features of a single foregoing disclosed aspect, embodiment, and/or configuration. Thus, the following claims are hereby incorporated into this Detailed Description, with each claim standing on its own as a separate preferred embodiment of the disclosure.

[0109] Moreover, though the description has included description of one or more aspects, embodiments, and/or configurations and certain variations and modifications, other variations, combinations, and modifications are within the scope of the disclosure, e.g., as may be within the skill and knowledge of those in the art, after understanding the present disclosure. It is intended to obtain rights which include alternative aspects, embodiments, and/or configurations to the extent permitted, including alternate, interchangeable and/or equivalent structures, functions, ranges or steps to those claimed, whether or not such alternate, interchangeable and/or equivalent structures, functions, ranges or steps are disclosed herein, and without intending to publicly dedicate any patentable subject matter.