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.

What is claimed as invention is: 
     
         1 . A photovoltaic module comprising four frame members, wherein:
 each of said frame members comprises an inward facing groove and an outward facing groove, said inward facing grooves at least partially retaining a photovoltaic laminate, said outward facing grooves located substantially beneath said photovoltaic laminate.   
     
     
         2 . A photovoltaic module according to  claim 1 , wherein at least half a depth of at least one of said outward facing grooves is located substantially beneath said photovoltaic laminate. 
     
     
         3 . A photovoltaic module according to  claim 1 , wherein said outward facing grooves are adapted to connect to a coupling, said coupling adapted to connect said photovoltaic module to an adjacent photovoltaic module. 
     
     
         4 . A photovoltaic module according to  claim 3 , wherein said coupling comprises a bracket adapted to connect said photovoltaic module to a support structure. 
     
     
         5 . A photovoltaic module according to  claim 1 , wherein at least a portion of at least one of said frame members is essentially hollow. 
     
     
         6 . A photovoltaic module according to  claim 1 , wherein a first and a second frame members of said four frame members are orthogonally connected. 
     
     
         7 . A photovoltaic module according to  claim 1 , wherein said four frame members are each connected substantially at an end to another frame member to form four corners. 
     
     
         8 . A photovoltaic module according to  claim 1 , wherein two of said four frame members are each connected substantially at an end thereof to form a corner. 
     
     
         9 . A photovoltaic module according to  claim 8 , wherein said outward facing grooves of said two of said four frame members are essentially continuous with each other through said corner. 
     
     
         10 . A photovoltaic module according to  claim 8 , wherein said outward facing grooves of said two of said four frame members have essentially the same height at said corner, and are essentially contiguous at said corner. 
     
     
         11 . A photovoltaic module according to  claim 1 , wherein said outward facing grooves extend essentially all the way around said frame. 
     
     
         12 . A photovoltaic module comprising a frame, wherein:
 said frame comprises an inward facing groove and an outward facing groove, said inward facing groove at least partially retaining a photovoltaic laminate, at least half of said outward facing groove located substantially beneath said photovoltaic laminate and comprising a cavity, said cavity comprising a height and a depth, a ratio of said height to said depth being greater than 1.5 to 1.   
     
     
         13 . A photovoltaic module according to  claim 12 , wherein at least a portion of said cavity is located behind a lip. 
     
     
         14 . A photovoltaic module according to  claim 12 , wherein said outward facing grooves are adapted to connect to a coupling. 
     
     
         15 . A photovoltaic module according to  claim 14 , wherein said coupling comprises a bracket adapted to connect said photovoltaic module to a support structure. 
     
     
         16 . A photovoltaic module according to  claim 12 , wherein at least a portion of said frame is essentially hollow. 
     
     
         17 . A photovoltaic module comprising a frame, wherein:
 said frame comprises an inward facing groove and an outward facing groove, said inward facing groove at least partially retaining a photovoltaic laminate, said outward facing groove comprising a substantially horizontal support portion, said support portion supporting a bottom of said outward facing groove and having a height substantially greater than a thickness of an upper flange of said inward facing groove.   
     
     
         18 . A photovoltaic module according to  claim 17 , wherein at least a portion of said support portion is essentially hollow. 
     
     
         19 . A photovoltaic module according to  claim 17 , wherein at least half a depth of said outward facing groove is located substantially beneath said photovoltaic laminate. 
     
     
         20 . A photovoltaic module according to  claim 17 , wherein said outward facing groove is adapted to connect to a coupling, said coupling adapted to connect said photovoltaic module to an adjacent photovoltaic module. 
     
     
         21 . A photovoltaic module according to  claim 20 , wherein said coupling comprises a bracket adapted to connect said photovoltaic module to a support structure. 
     
     
         22 . A photovoltaic module comprising a frame, wherein:
 said frame comprises an inward facing groove, an outward facing groove, and a downward facing portion, said inward facing groove at least partially retaining a photovoltaic laminate, said outward facing groove comprising a generally upward facing inner portion, said downward facing portion being substantially beneath said inner portion, said inner portion located behind a substantially vertical lip of said outward facing groove, a distance between said inner portion and said downward facing portion having a height substantially greater than a thickness of an upper flange of said inward facing groove.   
     
     
         23 . A photovoltaic module according to  claim 22 , wherein at least a portion of said frame between said inner portion and said downward facing portion is hollow. 
     
     
         24 . A photovoltaic module according to  claim 23 , wherein substantially all of said frame between said inner portion and said downward facing portion is hollow. 
     
     
         25 . A photovoltaic module according to  claim 22 , wherein said outward facing grooves are adapted to connect to a coupling, said coupling adapted to connect said photovoltaic module to an adjacent photovoltaic module. 
     
     
         26 . A photovoltaic module according to  claim 25 , wherein said coupling comprises a bracket adapted to connect said photovoltaic module to a support structure. 
     
     
         27 . A photovoltaic module according to  claim 22 , wherein said vertical lip is a flange. 
     
     
         28 . A photovoltaic module according to  claim 22 , wherein said outward facing groove further comprises a second lip substantially facing said vertical lip. 
     
     
         29 . A photovoltaic module according to  claim 22 , wherein an outside surface of said vertical lip is essentially flush with an outside surface of said frame. 
     
     
         30 . A photovoltaic module according to  claim 22 , wherein at least a portion of a distal surface of said vertical lip angles at least partly inward. 
     
     
         31 . A photovoltaic module comprising a frame, wherein:
 said frame comprises an inward facing groove and an outward facing groove, said inward facing groove at least partially retaining a photovoltaic laminate, said outward facing groove comprising at least one lip, said frame comprising a hollow portion located at least partially beneath said outward facing groove.   
     
     
         32 . A photovoltaic module according to  claim 31 , wherein said lip is a flange. 
     
     
         33 . A photovoltaic module according to  claim 31 , wherein said outward facing groove further comprises a second lip substantially facing said at least one lip. 
     
     
         34 . A photovoltaic module according to  claim 31 , wherein an outside surface of said at least one lip is essentially flush with an outside surface of said frame. 
     
     
         35 . A photovoltaic module according to  claim 31 , wherein at least a portion of a distal surface of said at least one lip angles at least partly inward.