Obviousness

Obviousness Analysis of US Patent 11967921 Under 35 U.S.C. § 103

This analysis assesses the obviousness of the claims of US Patent 11967921 (the '921 patent) under 35 U.S.C. § 103, considering the common knowledge of a person having ordinary skill in the art (PHOSITA) in the field of solar tracking technology prior to the effective filing date of December 22, 2014.

Limitation on Prior Art Content:
The provided patent text includes a "CROSS REFERENCE TO RELATED APPLICATION" section, listing several related U.S. patent applications and provisional applications, some of which precede the '921 patent's priority date of December 22, 2014. These earlier applications (U.S. application Ser. No. 14/101,273 filed Dec. 9, 2013, and U.S. Provisional Application No. 61/735,537 filed Dec. 10, 2012) could constitute prior art. However, the full textual content of these specific prior art documents has not been provided within the scope of this analysis. Therefore, a detailed obviousness analysis combining specific disclosures from these or other external prior art references is not possible.

Instead, this analysis will proceed by examining the claims of the '921 patent in light of the general knowledge in the field of solar tracking, as implied by the patent's background, and the well-understood motivations for combining known components in this technical area.

General Principles of Obviousness and Motivation to Combine

For a claim to be obvious, the differences between the claimed invention and the prior art must be such that the subject matter as a whole would have been obvious at the time the invention was made to a PHOSITA. This often involves showing that a PHOSITA would have been motivated to combine known elements from the prior art to achieve the claimed invention, with a reasonable expectation of success. Common motivations include:

• Improving performance (e.g., efficiency, tracking accuracy, load handling).
• Reducing manufacturing or installation costs.
• Simplifying assembly or maintenance.
• Addressing known problems or design challenges in the field.
• Achieving a known desirable result using known means.

The '921 patent's background acknowledges that "conventional solar tracking mechanisms have been developed" but were "often inadequate," [cite: "Although solar panels have been used successfully for certain applications, there are still limitations. Often, solar panels are unable to convert energy at their full potential due to the fact that the sun is often at an angle that is not optimum for the solar cells to receive solar energy. In the past, various types of conventional solar tracking mechanisms have been developed. Unfortunately, conventional solar tracking techniques are often inadequate."] implying the existence of basic solar tracker components as known prior art.

Analysis of Independent Claims

Independent Claim 1: Self-Powered Solar Tracker Apparatus

Key Elements (summarized from claim description):

• Frame assembly holding solar modules.
• Drive device to move the frame assembly.
• Energy system powering the drive device, comprising:
  • Solar panel energy source (less than 300 Watts).
  • DC-to-DC converter.
  • Battery storage device.
  • Boost converter.
  • Capacitor device (provides stable voltage for motor drive).
  • Micro-controller (with inputs for motor current/voltage, battery temperature, solar panel current/voltage, battery current/voltage, and control signals for battery charger, boost converter, motor drive).
• Energy system configured to operate with less than 15 Watt-hours per day without an external energy source.

Obviousness Argument:
The individual components of Claim 1 are widely known in the art of electronics and solar power management prior to 2014.

• Frame assemblies for solar modules and drive devices for solar trackers were standard.
• Solar panels for energy generation, DC-to-DC converters for voltage regulation, battery storage devices for energy buffering, boost converters for voltage step-up, and capacitors for voltage stabilization were all fundamental electronic components and power management techniques.
• Microcontrollers were routinely used for monitoring, control, and automation in various systems, including energy management and motor control.

A PHOSITA, faced with the common problem of providing power to a remote solar tracker without relying on external grid connections, would have been highly motivated to combine these known elements to create a self-powered system. The desire to make the tracker "free from external power lines" [cite: "the energy system is configured to supply power to the motor to cause the tracker apparatus to operate with less than 15 Watt-hours per day of operation without an external energy source to provide a self powered tracker that is free from external power lines or the like."] is a strong motivation for such a combination. The specific limits on solar panel wattage (e.g., "less than about 300 Watts") [cite: "the solar panel energy source being less than about 300 Watts or other variation."] and daily energy consumption ("less than 15 Watt-hours per day") [cite: "the energy system is configured to supply power to the motor to cause the tracker apparatus to operate with less than 15 Watt-hours per day of operation without an external energy source to provide a self powered tracker that is free from external power lines or the like."] represent design choices and optimization goals common in developing efficient, off-grid power systems, rather than inventive structural features. The microcontroller's functions (monitoring currents/voltages, controlling chargers/converters/motors) are standard applications for such devices in a self-powered system.

Independent Claim 13: Method for Assembling a Solar Tracker Apparatus

Key Elements (summarized from claim description):

1. Providing a clamp housing member with an upper region including a spherical bearing device, the lower region coupled to a pier structure.
2. Coupling a clam shell clamp to the spherical bearing device, being suspended therefrom.
3. Supporting a torque tube between the clam shell clamp halves, the torque tube being configured in an off-set position from a center region of rotation.
4. Coupling a pin to the first half clam shell clamp, the second half clam shell clamp, and the spherical bearing device.
5. Coupling the first and second clam shell clamp members to sandwich the spherical bearing device to a tongue region of the upper region of the clamp housing member.

Obviousness Argument:
The method describes a specific assembly sequence for a mechanical support structure.

• Piers as support structures are fundamental to ground-mounted solar trackers.
• Clamp housing members and clam shell clamps are known mechanical fastening elements.
• Spherical bearing devices were known in mechanical engineering prior to 2014 for accommodating misalignment, thermal expansion, and construction tolerances, as well as enabling multi-axis rotation. The patent explicitly states that the spherical bearing "allows for accommodation of a construction tolerance, tracker movement, and acts as a bonding path of least resistance for taking an electrical current to ground." [cite: "the spherical bearing device 1130 allows for accommodation of a construction tolerance, tracker movement, and acts as a bonding path of least resistance for taking an electrical current to ground."].
• Torque tubes are core components of horizontal single-axis trackers.
• The concept of supporting a rotating element (torque tube) with an offset center of rotation is a known mechanical design technique, potentially to reduce motor load or improve stability.
• Pins and bolts are standard fasteners.

A PHOSITA would be motivated to combine these known mechanical components and assembly techniques to create a robust and adjustable support for a solar tracker. The specific steps of suspending a clam shell clamp from a spherical bearing, and then using the clamp to hold an offset torque tube, represent a logical combination of known mechanical elements to achieve adjustability and support for a long, rotating structure, particularly to manage construction tolerances and structural loads. The benefits of such a design in terms of ease of installation and tolerance accommodation would be well understood.

Independent Claim 14: Solar Tracker Apparatus with Suspended Torque Tube

Key Elements (summarized from claim description):

• Clamp housing member configured upright, with lower region coupled to a pier structure and upper region including a spherical bearing device.
• Clam shell clamp housing member coupled to and suspended from the spherical bearing.
• Torque tube with first end coupled to the spherical bearing device, supported from the upper region of the clamp housing member, and configured in an off-set position from a center region of rotation.
• Drive device coupled to the second end, configured to be "substantially free from a twisting action while under a load".

Obviousness Argument:
This claim defines the apparatus produced by the method of Claim 13. The structural arrangement of the clamp housing, spherical bearing, and suspended clam shell clamp supporting an offset torque tube is a specific implementation of known mechanical principles.

• The upright clamp housing member supporting the spherical bearing on a pier is a standard way to provide a pivot point.
• Suspending the torque tube from the spherical bearing via a clam shell clamp is a design choice that leverages the spherical bearing's multi-directional articulation for tolerance accommodation and rotational freedom.
• The offset position from a center region of rotation for the torque tube is a known engineering approach to balance forces or optimize the mechanical advantage of the drive system.
• Designing the drive device and torque tube to be substantially free from twisting under load is a fundamental goal in mechanical system design, particularly for long structures under torsional stress (like a torque tube with solar panels facing wind loads). This would be achieved by using adequately strong materials, appropriate connection mechanisms, and potentially by distributing loads or balancing the system, all of which are standard engineering considerations.

A PHOSITA would be motivated to create a support system that provides adjustability, accommodates tolerances, and minimizes twisting under operational loads. Combining a spherical bearing for multi-axis movement with a clam shell clamp for securing a torque tube in an offset configuration, and integrating a robust drive mechanism, would be an obvious engineering solution to these known problems in solar tracker design.

Independent Claim 15: Solar Tracker Apparatus with Offset Crank and Housing Stops

Key Elements (summarized from claim description):

• Drive device with a crank coupled in an offset manner to a continuous torque tube (plurality of cylindrical torque tubes).
• Frame assembly coupled to the continuous torque tube, coupled to solar modules.
• Clamp assembly housing coupled to a second end of the continuous torque tube, suspending the torque tube from the housing.
• Housing with an opening comprising first and second inner regions acting as stops for radial movement.
• Drive motor operable to move the torque tube about a center of rotation, substantially free from a load and moving at substantially the same force from a first to a second radial position.
• Center of rotation offset from the center of the continuous torque tube via the offset crank.

Obviousness Argument:
This claim focuses on the drive mechanism and the range-of-motion control.

• Crank mechanisms are well-known for converting rotary to oscillatory motion or vice versa, and for providing mechanical advantage in drive systems. An offset crank is a specific variant used to achieve desired motion profiles or leverage.
• Mechanical stops (the "first and second inner regions" of the housing opening) [cite: "the opening comprises a first inner region and a second inner region the first inner region acts as a first stop for the continuous torque tube when moved in a first radial direction until contact with the first inner region the second inner region acts as a second stop for the continuous torque tube when moved in a second radial direction until contact with the second inner region."] are conventional features in mechanical systems to limit the range of motion and prevent over-rotation or damage.
• The goal of having the drive motor operate "substantially free from a load" and with "substantially a same force" while moving an offset torque tube indicates a design that achieves balanced forces throughout the range of motion. This is a common objective in mechanical design to reduce motor wear and power consumption, achievable through proper sizing, balancing, and mechanical linkage design. The "center of mass aligned with a center of rotation" [cite: "the center of mass is aligned with a center of rotation of the cylindrical torque tubes to reduce a load of a motor operably coupled to the cylindrical torque tube."] (as stated in the Abstract and Claim 1's description) directly contributes to this reduced load.

A PHOSITA would be motivated to design a drive system that efficiently and reliably moves the solar modules. Using an offset crank for specific kinematic or load-balancing benefits, incorporating stops for safety and operational limits, and striving for uniform motor loading are all standard engineering practices in designing automated systems. Combining these known elements to create a tracker drive with defined motion limits and optimized load characteristics would be obvious.

Independent Claim 16: Solar Tracker Apparatus with Dual Cranks and Swage Fittings

Key Elements (summarized from claim description):

• Drive device including a first crank (1541) coupled to a first side and a second crank (1542) coupled to a second side of the drive device.
• A first torque tube coupled to the first crank (1541) via a first swage fitting.
• A second torque tube coupled to the second crank (1542) via a second swage fitting.
• A second pier coupled to the drive device, with a drive mount coupled to the second pier.

Obviousness Argument:
This claim details the connection of a drive device to a segmented torque tube.

• Using multiple cranks (first and second) on either side of a drive device to transmit power to two segments of a continuous torque tube is a straightforward mechanical design for spanning longer rows or distributing torque.
• Swage fittings are a well-established and known method for mechanically joining tubular components without welding. The patent itself highlights their advantages: "Reduced welding lowers cost, improves installation time, avoids errors in installation, improves manufacturability, and reduces component count through standardized parts. The torque tube is coupled to another torque tube via a swage device within a vicinity of the clam shell clamp housing member. In an embodiment, the connection is low cost, and provides for strong axial and torsional loading." [cite: "Reduced welding lowers cost, improves installation time, avoids errors in installation, improves manufacturability, and reduces component count through standardized parts. The torque tube is coupled to another torque tube via a swage device within a vicinity of the clam shell clamp housing member. In an embodiment, the connection is low cost, and provides for strong axial and torsional loading."].
• Piers and drive mounts are standard support structures.

A PHOSITA would be motivated to select joining methods that are efficient, cost-effective, and provide sufficient structural integrity for long torque tubes in a solar tracker. Swage fittings, known for their strong axial and torsional loading capabilities and ease of installation compared to welding, would be an obvious choice for connecting torque tube segments to cranks in a modular tracker system. This combination directly addresses the need for scalable and easily assembled tracker rows.

Independent Claim 17: Solar Tracker Apparatus with Welds-Free, Swage-Fitted Steel Torque Tubes

Key Elements (summarized from claim description):

• Plurality of torque tubes (first to Nth, N>2) coupled together "free from any welds".
• Each pair of torque tubes "swage-fitted together".
• Each torque tube is cylindrical in shape and made of steel.
• Each of the plurality of torque tubes characterized by a length greater than 80 meters.
• Each torque tube includes a plurality of notches.
• Plurality of U-bolt devices coupled respectively to the plurality of notches.

Obviousness Argument:
This claim focuses on the construction of the extended torque tube.

• Cylindrical steel torque tubes are the standard for transmitting torque in solar trackers.
• The desire for connections "free from any welds" [cite: "Each pair of torque tubes is coupled to each other free from any welds."] is a clear motivation for using alternative joining methods, given the costs, complexity, and potential quality issues associated with field welding, especially for large-scale projects.
• Swage fittings are explicitly presented in the patent as a superior alternative, providing "low cost" and "strong axial and torsional loading" connections [cite: "Reduced welding lowers cost, improves installation time, avoids errors in installation, improves manufacturability, and reduces component count through standardized parts. The torque tube is coupled to another torque tube via a swage device within a vicinity of the clam shell clamp housing member. In an embodiment, the connection is low cost, and provides for strong axial and torsional loading."]. Their use for joining tube segments would be obvious to a PHOSITA seeking these benefits.
• The length of "greater than 80 meters" [cite: "Each of the plurality of torque tubes is characterized by a length greater than 80 meters."] indicates large-scale applications where modularity and efficient joining are critical.
• Notches on tubes and U-bolt devices for coupling to them are well-known mechanical fastening techniques, providing secure attachment points for additional components (like solar module frames) and preventing rotational slippage.

A PHOSITA designing a large-scale solar tracker would be motivated to use readily available, strong, and cost-effective materials like steel for torque tubes. The need for long rows (e.g., >80m) would necessitate modular construction. The explicit advantages of "reduced welding" [cite: "Reduced welding lowers cost, improves installation time, avoids errors in installation, improves manufacturability, and reduces component count through standardized parts."] would drive the choice of a non-welded, strong connection like swage-fitting. Combining swage-fitted segments with U-bolts and notches for module attachment are all known, logical, and highly motivated choices for constructing robust and efficiently assembled long torque tubes.

Independent Claim 18: Tracker Apparatus with Six-Directional Movable Clamp Holding Member

Key Elements (summarized from claim description):

• Pier member including a lower region and an upper region.
• Clamp holding member configured to the upper region and capable of moving in at least a first direction, a second direction opposite to the first direction, a third direction normal to the first direction and the second direction, a fourth direction opposite to the third direction, a fifth direction normal to the first, second, third, and fourth directions, and a sixth direction opposite to the fifth direction.

Obviousness Argument:
This claim describes a highly adjustable connection.

• Piers are standard support elements.
• The ability of a clamp holding member to move in six degrees of freedom (translation along three axes and rotation about three axes, implied by "first, second, third, fourth, fifth, and sixth directions" in opposite and normal orientations) is a known engineering goal for components that need to accommodate significant misalignment, whether due to manufacturing tolerances, uneven ground, or installation inaccuracies. This adjustability is often achieved through combinations of slotted holes, spherical bearings, sliding mechanisms, or articulated joints.

A PHOSITA would be acutely aware of the challenges posed by construction tolerances and uneven terrain in deploying large-scale solar tracker arrays. They would be highly motivated to design a support or clamp holding member that provides substantial adjustability to ensure proper alignment of the tracker system. Implementing a connection capable of such multi-directional movement using known mechanical principles and elements (e.g., slotted connections, spherical bearings, universal joints) would be an obvious design solution to overcome these practical challenges.

Conclusion

Based on the information available, the independent claims of US Patent 11967921 appear to define combinations of known components and engineering principles in the field of solar tracking. While the lack of specific, full-content prior art references prevents a detailed, document-specific obviousness analysis, the general motivations for combining these elements were well-understood by a PHOSITA before the priority date of December 22, 2014. These motivations include:

• Reducing installation and manufacturing costs (e.g., self-powered system, weld-free connections, modularity).
• Improving operational efficiency and reliability (e.g., reduced motor load through aligned center of mass/rotation, stable voltage for motor drive).
• Accommodating construction and terrain tolerances (e.g., spherical bearings, multi-directional adjustability).
• Ensuring structural integrity and limiting motion (e.g., swage fittings for strong connections, mechanical stops, robust design against twisting).

A PHOSITA, seeking to overcome the known limitations of conventional solar tracking mechanisms and to develop more efficient, cost-effective, and robust systems, would have found it obvious to combine these well-known components and apply these established engineering principles to achieve the results claimed in US Patent 11967921.