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 with an outward facing groove and a coupling, said coupling comprising a locking portion, said outward facing groove comprising a locking portion stop, and said locking portion comprising a radially extending portion adapted to resist rotation of said locking portion beyond a predetermined rotational position. 
     
     
         2 . A photovoltaic module according to  claim 1 , wherein said coupling is adapted to rotate essentially about an axis, said radially extending portion extending radially from said axis. 
     
     
         3 . A photovoltaic module according to  claim 1 , wherein said locking portion comprises a key portion. 
     
     
         4 . A photovoltaic module according to  claim 1 , wherein said locking portion stop is a hard stop. 
     
     
         5 . A photovoltaic module according to  claim 4 , wherein said hard stop is adapted to inhibit rotation of said coupling beyond said predetermined rotational position. 
     
     
         6 . A photovoltaic module according to  claim 4 , wherein said hard stop is adapted to inhibit rotation of said coupling after connection to said frame. 
     
     
         7 . A photovoltaic module according to  claim 1 , wherein said coupling is not wider than a width of said photovoltaic module. 
     
     
         8 . A photovoltaic module according to  claim 1 , wherein said locking portion has at least one tapered surface, said at least one tapered surface at least partially leading said key portion further into said outward facing groove upon rotation of said coupling. 
     
     
         9 . A photovoltaic module according to  claim 1 , wherein rotation of said coupling rotates said locking portion such that said locking portion connects with said frame. 
     
     
         10 . A photovoltaic module according to  claim 1 , wherein rotation of said coupling rotates said locking portion such that said frame captures said locking portion. 
     
     
         11 . A photovoltaic module according to  claim 1 , wherein said radially extending portion has at least one tapered surface said at least one tapered surface at least partially leading said key portion further into said outward facing groove upon rotation of said coupling. 
     
     
         12 . A photovoltaic module according to  claim 1 , wherein said radially extending portion comprises two substantially curved surfaces on opposite corners. 
     
     
         13 . A photovoltaic module according to  claim 1 , wherein said outward facing groove comprises a slot. 
     
     
         14 . A photovoltaic module comprising a frame with an outward facing groove and a coupling, wherein:
 said coupling comprises a key having a width slightly less than a height of an opening of said outward facing groove and a longest dimension approximately equal to a height inside of said outward facing groove.   
     
     
         15 . A photovoltaic module according to  claim 14 , wherein said width is approximately 0.7 to 0.9 times said height of said opening of said outward facing groove. 
     
     
         16 . A photovoltaic module according to  claim 14 , wherein said key is adapted to rotatably engage with said frame. 
     
     
         17 . A photovoltaic module according to  claim 14 , wherein said longest dimension in an insertion position essentially aligns with said outward facing groove. 
     
     
         18 . A photovoltaic module according to  claim 14 , wherein said outward facing groove extends substantially the length of a frame member of said frame. 
     
     
         19 . A photovoltaic module according to  claim 14 , wherein said key comprises a locking portion. 
     
     
         20 . A photovoltaic module according to  claim 14 , wherein said key has at least one tapered surface, said at least one tapered surface at least partially leading said key further into said outward facing groove upon rotation of said coupling. 
     
     
         21 . A photovoltaic module according to  claim 14 , wherein said outward facing groove comprises a locking portion stop. 
     
     
         22 . A photovoltaic module according to  claim 14 , wherein said outward facing groove comprises a slot.