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 having a groove, said groove comprising an upper lip and a lower lip, wherein:
 each of said upper and lower lips is oriented substantially vertically, and   a height of said upper lip is less than or equal to a thickness of said upper lip and a height of said lower lip is less than or equal to a thickness of said lower lip, wherein said lower lip is supported by a horizontal portion, a distance from a bottom of said horizontal portion to a top of said lower lip is greater than or equal to two times said height of said lower lip.   
     
     
         2 . A photovoltaic module according to  claim 1 , wherein at least one of said upper and lower lips is a flange. 
     
     
         3 . A photovoltaic module according to  claim 1 , wherein an outermost surface of said upper lip is substantially flush with a portion of an outside surface of said frame member, said portion located substantially above said upper and lower lips. 
     
     
         4 . A photovoltaic module according to  claim 1 , wherein said groove comprises an end opening located at an end of said groove and a lateral opening, said upper and lower lips bounding said lateral opening of said groove. 
     
     
         5 . A photovoltaic module according to  claim 4 , wherein a height of said lateral opening is greater than or equal to a depth of said groove. 
     
     
         6 . A photovoltaic module according to  claim 4 , wherein a maximum height of said lateral opening is less than a maximum height inside said groove. 
     
     
         7 . A photovoltaic module comprising a frame member having an outward facing groove, wherein:
 a distance from a centerline of said groove to a lower surface of an upper lip of said groove substantially increases in a direction away from a back wall of said groove, said lower surface forming an upper boundary of said groove.   
     
     
         8 . A photovoltaic module according to  claim 7 , wherein said direction is substantially perpendicular to said back wall. 
     
     
         9 . A photovoltaic module according to  claim 7 , wherein said groove extends substantially an entire length of said frame, said groove comprising an upper flange and a lower flange bounding an opening to said groove, said upper flange comprising an inner lower portion and an outer lower portion and said lower portions defining one or more inner surfaces of said groove, wherein said inner lower portion is located substantially closer to a centerline of said opening than said outer lower portion. 
     
     
         10 . A photovoltaic module according to  claim 7 , wherein said portion of said lower surface is adapted to lead in at least a portion of a coupling. 
     
     
         11 . A photovoltaic module according to  claim 7 , wherein an outside surface of said lip is essentially flush with an outside surface of said frame member. 
     
     
         12 . A photovoltaic module according to  claim 9 , wherein said upper and lower flanges bound a lateral entry of said groove, said lateral entry located at least 0.5 inches from a corner of said photovoltaic module. 
     
     
         13 . A photovoltaic module according to  claim 12 , wherein a height of said lateral entry is greater than or equal to a depth of said groove. 
     
     
         14 . A photovoltaic module comprising a frame member having a groove, said groove comprising a first lip and a second lip, wherein:
 said frame comprises a fully enclosed hollow portion, at least a portion of said hollow portion located beneath said groove.   
     
     
         15 . A photovoltaic module according to  claim 14 , wherein said first and second lips are adapted to provide high pull-out strength of a coupling. 
     
     
         16 . A photovoltaic module according to  claim 14 , wherein said first and second lips run substantially a full length of said frame member and are adapted to engage a male protrusion of a coupling. 
     
     
         17 . A photovoltaic module according to  claim 14 , wherein said lips are adapted to engage a grounding portion of a coupling. 
     
     
         18 . A photovoltaic module according to  claim 14 , wherein at least one of said first and second lips is a flange. 
     
     
         19 . A photovoltaic module according to  claim 14 , wherein an outside surface of said first lip is essentially flush with an outside surface of said frame member, said outside surface of said frame member located above said first and second lips. 
     
     
         20 . A photovoltaic module according to  claim 14 , wherein a height of a lateral entry is greater than or equal to a depth of said groove, wherein a direction of said lateral entry and said depth are substantially perpendicular to a back wall of said groove. 
     
     
         21 . A photovoltaic module according to  claim 1 , wherein said height of said lower lip is measured along an inside surface of said groove. 
     
     
         22 . A photovoltaic module according to  claim 9 , wherein a line between said lower portions extends at an angle greater than 5 degrees. 
     
     
         23 . A photovoltaic module according to  claim 9 , wherein a line between said lower portions extends at an angle greater than 45 degrees.