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 member comprising a groove having at least one lip, said groove being adapted to receive at least a portion of a coupling, said coupling comprising a length along a longest dimension of said coupling, a first engaging portion, and a second engaging portion, said groove opening in a lateral direction essentially parallel with a plane of a photovoltaic laminate of said photovoltaic module and being further adapted to engage with said first engaging portion in a direction substantially perpendicular to said length, an adjacent groove on a frame member of an adjacent photovoltaic module opening in a same direction as said groove, being located in a position substantially collinear with said groove, and being adapted to engage with said second engaging portion in said direction substantially perpendicular to said length.   
     
     
         2 . The photovoltaic module of  claim 1 , wherein said coupling comprises a series coupling adapted to couple said photovoltaic module to said adjacent photovoltaic module. 
     
     
         3 . The photovoltaic module of  claim 1 , wherein said first groove is adapted to engage with said first engaging portion at various positions within a predetermined distance from an end of said first frame member. 
     
     
         4 . The photovoltaic module of  claim 1 , wherein said coupling further comprises a bracket portion adapted to connect at least a portion of said photovoltaic module to a support structure. 
     
     
         5 . The photovoltaic module of  claim 1 , wherein said coupling further comprises a bracket portion adapted to connect at least a portion of said photovoltaic module above a support structure. 
     
     
         6 . The photovoltaic module of  claim 5 , wherein said coupling further comprises a bracket portion adapted to connect at least a portion of said photovoltaic module a field adjustable distance above a support structure. 
     
     
         7 . The photovoltaic module of  claim 1 , wherein said photovoltaic module and said adjacent photovoltaic module are adapted to receive said coupling after being located in their substantially final position relative to a support structure. 
     
     
         8 . The photovoltaic array of  claim 1 , wherein said frame members each comprise an outside surface, said groove extending along a substantial portion of said outside surface. 
     
     
         9 . The photovoltaic array of  claim 1 , wherein said coupling comprises a series-parallel coupling. 
     
     
         10 . A photovoltaic module according to  claim 1 , wherein said lip is a flange. 
     
     
         11 . A photovoltaic module according to  claim 1 , wherein said lip comprises two lips essentially facing each other. 
     
     
         12 . 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 member. 
     
     
         13 . A first and second photovoltaic module connected together with a coupling, each of said first and second photovoltaic modules comprising a frame with an outward facing groove, wherein:
 said coupling comprises a first engaging portion positioned within said outward facing groove of said first photovoltaic module and a second engaging portion positioned within said outward facing groove of said second photovoltaic module, said first engaging portion at least partially supporting said first photovoltaic module, said outward facing groove of said first photovoltaic module located essentially collinear to said outward facing groove of said second photovoltaic module and extending at least partially beneath a photovoltaic laminate.   
     
     
         14 . A photovoltaic module according to  claim 13 , wherein said coupling comprises a bracket adapted to connect at least a portion of said first photovoltaic module to a support structure. 
     
     
         15 . A photovoltaic module according to  claim 13 , wherein said coupling comprises a bracket adapted to connect at least a portion of said first photovoltaic module above a support structure. 
     
     
         16 . A photovoltaic module according to  claim 15 , wherein said bracket is adapted to adjust a height of said first and second photovoltaic modules. 
     
     
         17 . A photovoltaic module according to  claim 13 , wherein said second engaging portion at least partially supports said second module. 
     
     
         18 . A photovoltaic module according to  claim 13 , wherein said first engaging portion provides a ground bond between said first and second photovoltaic modules and said coupling. 
     
     
         19 . A photovoltaic module according to  claim 13 , wherein said first engaging portion at least partially supports said first PV module above said support structure. 
     
     
         20 . A photovoltaic module according to  claim 13 , wherein said outward facing groove of said first photovoltaic module comprises at least one lip. 
     
     
         21 . A photovoltaic module according to  claim 20 , wherein said outward facing groove of said first photovoltaic module comprises two lips essentially facing each other. 
     
     
         22 . A photovoltaic module according to  claim 20 , wherein said lip is a flange. 
     
     
         23 . A photovoltaic module according to  claim 13 , wherein at least half a depth of said outward facing groove of said first photovoltaic module is located substantially beneath said photovoltaic laminate. 
     
     
         24 . A first and second photovoltaic module connected together with a coupling, each of said first and second photovoltaic modules comprising a frame with an outward facing groove, wherein:
 said coupling comprises a first engaging portion positioned within said outward facing groove of said first photovoltaic module, a second engaging portion positioned within said outward facing groove of said second photovoltaic module, and a length along a longest dimension of said coupling, said first engaging portion at least partially supporting said first photovoltaic module and adapted to engage with said outward facing groove of said first photovoltaic module in a direction substantially perpendicular to said length, said outward facing groove of said first photovoltaic module located essentially collinear to said outward facing groove of said second photovoltaic module and comprising at least one lip.   
     
     
         25 . A photovoltaic module according to  claim 24 , wherein said direction extends substantially parallel with a plane of said first photovoltaic module. 
     
     
         26 . A photovoltaic module according to  claim 24 , wherein said coupling comprises a bracket adapted to connect said photovoltaic module to a support structure. 
     
     
         27 . A photovoltaic module according to  claim 26 , wherein said bracket is adapted to adjust a height of said first and second photovoltaic modules. 
     
     
         28 . A photovoltaic module according to  claim 24 , wherein said coupling comprises a bracket adapted to connect said photovoltaic module above a support structure. 
     
     
         29 . A photovoltaic module according to  claim 24 , wherein said outward facing groove of said first photovoltaic module comprises two lips essentially facing each other. 
     
     
         30 . A photovoltaic module according to  claim 24 , wherein said outward facing groove of said first photovoltaic module extends at least partially beneath a photovoltaic laminate. 
     
     
         31 . A photovoltaic module according to  claim 30 , wherein at least half a depth of said groove is located substantially beneath a photovoltaic laminate. 
     
     
         32 . A photovoltaic module according to  claim 24 , wherein said outward facing groove of said first photovoltaic module and said outward facing groove of said second photovoltaic module extend substantially the length of said frame of said first and second photovoltaic modules respectively. 
     
     
         33 . A first and second photovoltaic module connected together with a coupling, each of said first and second photovoltaic modules comprising a frame with an outward facing groove, wherein:
 said outward facing groove opens in a lateral direction essentially parallel with a plane of a photovoltaic laminate of said first photovoltaic module and said coupling comprises a first engaging portion positioned essentially within said outward facing groove of said first photovoltaic module and a second engaging portion positioned essentially within said outward facing groove of said second photovoltaic module, said first engaging portion adapted to engage substantially along a length thereof, said length extending along a longest dimension of said outward facing groove of said first photovoltaic module.   
     
     
         34 . A photovoltaic module according to  claim 33 , wherein said length is longer than a height of said first engaging portion. 
     
     
         35 . A photovoltaic module according to  claim 33 , wherein said first engaging portion is adapted to support said first photovoltaic module along at least a portion of said length. 
     
     
         36 . A photovoltaic module according to  claim 33 , wherein said coupling has a length of approximately 3-12″. 
     
     
         37 . A photovoltaic module according to  claim 33 , wherein said coupling is further adapted to increase a stiffness of said frame relative to a z-axis load. 
     
     
         38 . A photovoltaic module according to  claim 33 , wherein said coupling is not fully contained within said groove. 
     
     
         39 . A photovoltaic module according to  claim 33 , wherein said coupling further comprises a lower flange located substantially beneath said frame. 
     
     
         40 . A photovoltaic module according to  claim 39 , wherein said coupling is adapted to reduce deformation of said frame under load. 
     
     
         41 . A photovoltaic module according to  claim 33 , wherein said outward facing groove of said first photovoltaic module comprises at least one lip. 
     
     
         42 . A photovoltaic module according to  claim 33 , wherein said outward facing groove of said first photovoltaic module comprises two lips essentially facing each other. 
     
     
         43 . A photovoltaic module according to  claim 41 , wherein said lip is a flange. 
     
     
         44 . A photovoltaic module according to  claim 33 , wherein at least half a depth of said outward facing groove of said first photovoltaic module is located substantially beneath said photovoltaic laminate. 
     
     
         45 . A coupling for connecting a first photovoltaic module to a second photovoltaic module, said photovoltaic modules each comprising a photovoltaic laminate and a frame member, said coupling comprising:
 a plate portion having a length parallel with a longest dimension of said frame member;   an upper male protrusion protruding from said plate portion in a direction substantially parallel with at least one of said photovoltaic laminates; and   a lower male protrusion protruding from said plate portion in said direction; wherein said coupling connects said frame member of said first photovoltaic module to said frame member of said second photovoltaic module end to end, said upper male protrusion resists an upward movement of said photovoltaic modules, said lower protrusion resists a downward movement of said photovoltaic modules, said upper and lower male protrusions extending along said length.   
     
     
         46 . A coupling according to  claim 45 , wherein said upper male protrusion comprises one or more male protrusions. 
     
     
         47 . A coupling according to  claim 45 , wherein said lower male protrusion comprises one or more male protrusions. 
     
     
         48 . A coupling according to  claim 45 , wherein said coupling comprises multiple pieces. 
     
     
         49 . A coupling according to  claim 45 , wherein said coupling comprises a series coupling. 
     
     
         50 . A coupling according to  claim 45 , wherein said coupling comprises a series-parallel coupling. 
     
     
         51 . A coupling according to  claim 45 , wherein said frame members are collinear. 
     
     
         52 . A coupling according to  claim 45 , wherein said plate portion comprises a height similar to a height of at least one of said frame members. 
     
     
         53 . A coupling according to  claim 45 , wherein said lower male protrusion protrudes substantially beneath said frame member of said first photovoltaic module.