Method and Apparatus for Forming and Mounting a Photovoltaic Array

Abstract

A photovoltaic (PV) module framing and coupling system enables the attachment of PV modules to a roof or other mounting surface without requiring the use of separate structural support members which attach directly to and span between multiple PV modules in a formed PV array. The apparatus provides a parallel coupling for securely interlocking the outside surfaces of parallel frame members together in a side to side arrangement to form an array with improved structural load distribution. The coupling may attach to a slot in the frame at substantially any position along the length of the frame thereby enabling the interconnection of adjacent PV modules along both an x and y axis. The apparatus may further provide a rotating portion and locking portion, mounting brackets for direct connection to a mounting surface, grounding teeth, and a twist-lock engagement means for interlocking and aligning PV modules in the array.

1 . A photovoltaic module having two or more frame members, a photovoltaic laminate, and a coupling, wherein:
 said coupling is adapted to connect said photovoltaic module to an adjacent photovoltaic module and comprises a bracket portion adapted to mount at least a portion of said photovoltaic module a field adjustable distance above a support structure.   
     
     
         2 . A photovoltaic module according to  claim 1 , wherein said bracket portion connects a portion of said photovoltaic module and a portion of said adjacent photovoltaic module to said support structure. 
     
     
         3 . A photovoltaic module according to  claim 1 , wherein said bracket portion comprises a slot for adjusting a distance between said support structure and said photovoltaic module. 
     
     
         4 . A photovoltaic module according to  claim 1 , wherein said coupling is adapted to move independently relative to said bracket portion. 
     
     
         5 . A photovoltaic module according to  claim 1 , wherein said coupling is adapted to move toward and away from a base of said bracket portion. 
     
     
         6 . A photovoltaic module according to  claim 1 , wherein a first frame member of said frame members comprises a first groove along a substantial portion of an outside surface of said first frame member. 
     
     
         7 . A photovoltaic module according to  claim 6 , wherein said coupling connects said first groove to a second groove located along a substantial portion of an outside surface of a second frame member on said adjacent photovoltaic module. 
     
     
         8 . A photovoltaic module comprising a coupling, wherein: said coupling is adapted to connect a first groove on an outside surface of said photovoltaic module to a second groove on an outside surface of an adjacent photovoltaic module, said coupling comprising a first and second engaging portions, said first engaging portion adapted to connect to said first groove, a portion of said second engaging portion adapted to support a portion of said adjacent photovoltaic module from within said second groove while a portion of said coupling is rotatably connected to said adjacent photovoltaic module. 
     
     
         9 . A photovoltaic module according to  claim 8 , wherein a height dimension of said second engaging portion is substantially less than or equal to a height dimension of said second groove. 
     
     
         10 . A photovoltaic module according to  claim 8 , wherein said second engaging portion comprises a flange, said flange adapted to resist lateral movement of said adjacent photovoltaic module. 
     
     
         11 . A photovoltaic module according to  claim 8 , wherein said second engaging portion permits said adjacent photovoltaic module to rest on a portion thereof. 
     
     
         12 . A photovoltaic module according to  claim 8 , wherein said coupling comprises a bracket portion adapted to mount at least a portion of said photovoltaic module a field adjustable distance above a support structure. 
     
     
         13 . A photovoltaic module according to  claim 12 , wherein said coupling is adapted to move toward and away from a base of said bracket portion. 
     
     
         14 . A photovoltaic module according to  claim 12 , wherein said field adjustable distance is substantially continuously adjustable. 
     
     
         15 . A photovoltaic module according to  claim 8 , wherein said first and second grooves face each other. 
     
     
         16 . A photovoltaic module according to  claim 8 , wherein said first engaging portion comprises a bolt. 
     
     
         17 . A photovoltaic module according to  claim 8 , wherein said second engaging portion comprises a bolt. 
     
     
         18 . A coupling for connecting a photovoltaic module to an adjacent photovoltaic module, wherein: said coupling comprises first and second engaging portions, said first engaging portion adapted to connect to said photovoltaic module, a portion of said second engaging portion adapted to support said adjacent photovoltaic module from within a groove of said adjacent photovoltaic module while a portion of said coupling rotatably connects said adjacent photovoltaic module to said coupling. 
     
     
         19 . A coupling according to  claim 18 , wherein said second engaging portion comprises a flange, said flange adapted to resist lateral movement of said adjacent photovoltaic module. 
     
     
         20 . A coupling according to  claim 18 , wherein said second engaging portion permits said adjacent photovoltaic module to rest on a portion thereof. 
     
     
         21 . A coupling according to  claim 18 , wherein said coupling comprises a bracket portion adapted to mount at least a portion of said photovoltaic module a field adjustable distance above a support structure. 
     
     
         22 . A photovoltaic module according to  claim 21 , wherein said coupling is adapted to move toward and away from a base of said bracket portion. 
     
     
         23 . A photovoltaic module according to  claim 21 , wherein said field adjustable distance is substantially continuously adjustable. 
     
     
         24 . A coupling according to  claim 18 , wherein said groove is located along a substantial portion of a length of a frame member of said adjacent photovoltaic module and said photovoltaic module comprises a groove located along a substantial portion of a length of a frame member of said photovoltaic module, said groove of said photovoltaic module facing said groove of said adjacent photovoltaic module. 
     
     
         25 . A coupling according to  claim 18 , wherein said first engaging portion comprises a bolt. 
     
     
         26 . A coupling according to  claim 18 , wherein said second engaging portion comprises a bolt.