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 comprising a frame, wherein:
 said frame comprises a multifunction groove, said multifunction groove comprising two lips and connected to a coupling and a bracket, said coupling located at a substantially different position from said bracket along a length of said groove, said coupling adapted to connect to an adjacent photovoltaic module.   
     
     
         2 . A photovoltaic module according to  claim 1 , wherein said length is along one side of said photovoltaic module. 
     
     
         3 . A photovoltaic module according to  claim 1 , wherein said coupling is connected to said adjacent photovoltaic module. 
     
     
         4 . A photovoltaic module according to  claim 1 , wherein said coupling is further adapted to connect to a multifunction groove of said adjacent photovoltaic module. 
     
     
         5 . A photovoltaic module according to  claim 1 , wherein said multifunction groove comprises a multifunction female channel portion. 
     
     
         6 . A photovoltaic module according to  claim 1 , wherein said frame comprises a hybrid, strut-like frame. 
     
     
         7 . A photovoltaic module according to  claim 1 , wherein said lips are facing each other. 
     
     
         8 . A photovoltaic module according to  claim 1 , wherein at least half a depth multifunction groove is located substantially beneath a photovoltaic laminate. 
     
     
         9 . A photovoltaic module according to  claim 1 , wherein said bracket is adapted to connect said photovoltaic module to a support structure. 
     
     
         10 . A photovoltaic module according to  claim 1 , wherein an outside surface of at least one of said lips is essentially flush with an outside surface of said frame. 
     
     
         11 . A photovoltaic module according to  claim 1 , wherein said two lips bound a lateral entry of said multifunction groove. 
     
     
         12 . A photovoltaic module according to  claim 11 , wherein a height of said lateral entry is greater than or equal to a depth of said multifunction groove. 
     
     
         13 . A photovoltaic module according to  claim 1 , wherein at least one of said lips is a flange. 
     
     
         14 . A photovoltaic module according to  claim 1 , wherein said bracket is adapted to connect said photovoltaic module to a support structure a field adjustable height above said support structure. 
     
     
         15 . A photovoltaic module according to  claim 1 , wherein said coupling comprises a series-parallel coupling. 
     
     
         16 . A photovoltaic module comprising a frame, wherein:
 said frame comprises a multifunction groove connected to a parallel coupling portion, a series coupling portion, and a bracket.   
     
     
         17 . A photovoltaic module according to  claim 16 , wherein said parallel coupling portion is adapted to connect said PV module to a second PV module, said series coupling portion is adapted to connect said PV module to a third PV module. 
     
     
         18 . A photovoltaic module according to  claim 16 , wherein at least half a depth of said multifunction groove is located substantially beneath a photovoltaic laminate. 
     
     
         19 . A photovoltaic module according to  claim 16 , wherein said bracket is adapted to connect said photovoltaic module to a support structure a field adjustable height above said support structure. 
     
     
         20 . A photovoltaic module comprising a first and second frame member, wherein:
 said first frame member comprises a multifunction groove connected to a coupling and a bracket, said coupling located at a substantially different position from said bracket along a length of said groove, said coupling adapted to connect to an adjacent photovoltaic module, and said second frame member orthogonally connected to said first frame member and comprising a multifunction groove.   
     
     
         21 . A photovoltaic module according to  claim 20 , wherein said length is along one side of said photovoltaic module. 
     
     
         22 . A photovoltaic module according to  claim 20 , wherein said coupling is connected to said adjacent photovoltaic module. 
     
     
         23 . A photovoltaic module according to  claim 20 , wherein said coupling is further adapted to connect to said multifunction groove of said adjacent photovoltaic module. 
     
     
         24 . A photovoltaic module according to  claim 20 , wherein said multifunction groove comprises a multifunction female channel portion. 
     
     
         25 . A photovoltaic module according to  claim 20 , wherein said frame comprises a hybrid, strut-like frame. 
     
     
         26 . A photovoltaic module according to  claim 20 , wherein at least half a depth of said multifunction groove is located substantially beneath a photovoltaic laminate. 
     
     
         27 . A photovoltaic module according to  claim 20 , wherein said first and second frame members are each connected substantially at an end thereof to form a corner, and said multifunction grooves of said first and second frame members are essentially continuous with each other through said corner. 
     
     
         28 . A photovoltaic module according to  claim 20 , wherein said first and second frame members are each connected substantially at an end thereof to form a corner, and said multifunction grooves of said first and second frame members have essentially the same height at said corner, and are essentially contiguous at said corner. 
     
     
         29 . A photovoltaic module according to  claim 20 , wherein said bracket is adapted to connect said photovoltaic module to a support structure a field adjustable height above said support structure. 
     
     
         30 . A photovoltaic module according to  claim 20 , wherein said coupling comprises a series-parallel coupling. 
     
     
         31 . A photovoltaic module comprising a frame, wherein:
 said frame comprises a multifunction groove, at least 50% of said multifunction groove located beneath a photovoltaic laminate of said photovoltaic module and connected to a coupling and a bracket, said coupling located at a substantially different position from said bracket along a length of said multifunction groove, said coupling adapted to connect to an adjacent photovoltaic module.   
     
     
         32 . A photovoltaic module according to  claim 30 , wherein said length is along one side of said photovoltaic module. 
     
     
         33 . A photovoltaic module according to  claim 30 , wherein said coupling is connected to said adjacent photovoltaic module. 
     
     
         34 . A photovoltaic module according to  claim 30 , wherein said coupling is further adapted to connect to a multifunction groove of said adjacent photovoltaic module. 
     
     
         35 . A photovoltaic module according to  claim 30 , wherein said multifunction groove comprises a multifunction female channel portion. 
     
     
         36 . A photovoltaic module according to  claim 30 , wherein said frame comprises a hybrid, strut-like frame. 
     
     
         37 . A photovoltaic module according to  claim 30 , wherein said bracket is adapted to connect said photovoltaic module to a support structure a field adjustable height above said support structure. 
     
     
         38 . A photovoltaic module according to  claim 30 , wherein said coupling comprises a series-parallel coupling. 
     
     
         39 . A photovoltaic module according to  claim 30 , wherein at least half a depth multifunction groove is located substantially beneath said photovoltaic laminate. 
     
     
         40 . A photovoltaic module according to  claim 1 , wherein said coupling comprises a second bracket adapted to connect said photovoltaic module to a support structure. 
     
     
         41 . A photovoltaic module according to  claim 20 , wherein said bracket is adapted to connect said photovoltaic module to a support structure. 
     
     
         42 . A photovoltaic module according to  claim 30 , wherein said bracket is adapted to connect said photovoltaic module to a support structure.