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 a frame with an outward facing groove and a coupling, wherein:
 said coupling comprises a key portion, said key portion adapted to insert into said outward facing groove in an essentially horizontal rotational position, said coupling connected to said frame with said key portion in an essentially non-horizontal rotational position.   
     
     
         2 . A photovoltaic module according to  claim 1 , wherein said key portion comprises a locking portion. 
     
     
         3 . A photovoltaic module according to  claim 1 , wherein said essentially non-horizontal rotational position is essentially vertical relative to a top face of said photovoltaic module. 
     
     
         4 . A photovoltaic module according to  claim 1 , wherein a length of said key portion in said essentially horizontal rotational position is substantially aligned with a length of said outward facing groove. 
     
     
         5 . A photovoltaic module according to  claim 1 , wherein said key portion in said essentially horizontal rotational position comprises a length, said length extending substantially parallel to a longest inner surface of said outward facing groove. 
     
     
         6 . A photovoltaic module according to  claim 1 , wherein said outward facing groove is adapted to receive said key portion at substantially any position along said outward facing groove. 
     
     
         7 . A photovoltaic module according to  claim 1 , wherein said outward facing groove extends substantially the length of a frame member of said frame. 
     
     
         8 . A photovoltaic module according to  claim 1 , wherein said key portion comprises a radially elongate portion, said radially elongate portion in said essentially non-horizontal rotational position positioned substantially not in alignment with a longest surface of said outward facing groove. 
     
     
         9 . A photovoltaic module according to  claim 8 , wherein said key portion in said essentially non-horizontal rotational position contacts an upper inside surface of said outward facing groove. 
     
     
         10 . A photovoltaic module according to  claim 8 , wherein said key portion in said essentially non-horizontal rotational position contacts a lower inside surface of said outward facing groove. 
     
     
         11 . A photovoltaic module according to  claim 1 , wherein said key portion in said essentially non-horizontal rotational position comprises a radially elongate portion, said radially elongate portion extending substantially non-parallel to a longest dimension of said outward facing groove. 
     
     
         12 . A photovoltaic module according to  claim 11 , wherein said key portion in said essentially non-horizontal rotational position contacts an upper inside surface of said outward facing groove. 
     
     
         13 . A photovoltaic module according to  claim 11 , wherein said key portion in said essentially non-horizontal rotational position contacts a lower inside surface of said outward facing groove. 
     
     
         14 . A photovoltaic module according to  claim 1 , wherein at least a portion of said key portion is adapted for capture behind a male portion of said groove. 
     
     
         15 . A photovoltaic module according to  claim 14 , wherein said male portion is a flange. 
     
     
         16 . A photovoltaic module according to  claim 1 , wherein said coupling is adapted to connect to said photovoltaic module in less than 180 degrees of rotation. 
     
     
         17 . A photovoltaic module according to  claim 1 , wherein said coupling is adapted to connect to said photovoltaic module in approximately 45 degrees of rotation. 
     
     
         18 . A photovoltaic module according to  claim 1 , wherein said key portion is adapted for insertion into said outward facing groove in a direction substantially perpendicular to a longest surface of said outward facing groove. 
     
     
         19 . A photovoltaic module according to  claim 1 , wherein said key portion deforms at least a portion of said frame when said key is positioned in said essentially non-horizontal rotational position. 
     
     
         20 . A photovoltaic module according to  claim 1 , wherein said coupling is not wider than a width of said photovoltaic module. 
     
     
         21 . A photovoltaic module according to  claim 1 , wherein said key 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. 
     
     
         22 . A photovoltaic module according to  claim 1 , wherein rotation of said coupling rotates said key portion such that said key portion connects with said frame. 
     
     
         23 . A photovoltaic module according to  claim 1 , wherein rotation of said coupling rotates said key portion such that said frame captures said key portion. 
     
     
         24 . A photovoltaic module according to  claim 1 , wherein said outward facing groove comprises a locking portion stop. 
     
     
         25 . A photovoltaic module according to  claim 24 , wherein said locking portion stop comprises a hard stop adapted to resist rotation of said coupling after connection to said frame. 
     
     
         26 . A photovoltaic module according to  claim 1 , wherein said key portion comprises a radially extending portion adapted to resist rotation of said key portion beyond a predetermined rotational position. 
     
     
         27 . A photovoltaic module according to  claim 1 , wherein said outward facing groove comprises a slot. 
     
     
         28 . A photovoltaic module comprising a frame with an outward facing groove and a coupling, wherein:
 said coupling comprises a key portion, said key portion adapted to insert into said outward facing groove in a first discrete rotational position, said coupling connected to said frame with said key portion in a second discrete rotational position, wherein said first and second discrete rotational positions are a non-negligible rotational distance apart.   
     
     
         29 . A photovoltaic module according to  claim 28 , wherein said key portion is a locking portion. 
     
     
         30 . A photovoltaic module according to  claim 28 , wherein at least a portion of said key portion is adapted for capture behind a male portion of said groove. 
     
     
         31 . A photovoltaic module according to  claim 30 , wherein said male portion is a flange. 
     
     
         32 . A photovoltaic module according to  claim 28 , wherein said first and second discrete rotational positions are approximately 90 degrees apart. 
     
     
         33 . A photovoltaic module according to  claim 28 , wherein said coupling is adapted to connect to said photovoltaic module in less than 180 degrees of rotation. 
     
     
         34 . A photovoltaic module according to  claim 33 , wherein said coupling is adapted to connect to said photovoltaic module in approximately 90 degrees of rotation. 
     
     
         35 . A photovoltaic module according to  claim 33 , wherein said coupling is adapted to connect to said photovoltaic module in approximately 45 degrees of rotation. 
     
     
         36 . A photovoltaic module according to  claim 28 , wherein said coupling is adapted to prevent rotation of said coupling past said second discrete rotational position. 
     
     
         37 . A photovoltaic module according to  claim 28 , wherein said key portion comprises at least one locking portion stop to inhibit rotation past said second discrete rotational position. 
     
     
         38 . A photovoltaic module according to  claim 28 , wherein said key portion is adapted for insertion into said outward facing groove in a direction substantially perpendicular to a longest dimension of said outward facing groove. 
     
     
         39 . A photovoltaic module according to  claim 28 , wherein said key portion locks to said frame in said second discrete rotational position. 
     
     
         40 . A photovoltaic module according to  claim 39 , wherein said key portion deforms at least a portion of said frame when said key portion is positioned in said second discrete rotational position. 
     
     
         41 . A photovoltaic module according to  claim 28 , wherein said coupling is not wider than a width of said photovoltaic module. 
     
     
         42 . A photovoltaic module according to  claim 28 , wherein said key 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. 
     
     
         43 . A photovoltaic module according to  claim 28 , wherein rotation of said coupling rotates said key portion such that said key portion connects with said frame. 
     
     
         44 . A photovoltaic module according to  claim 28 , wherein rotation of said coupling rotates said key portion such that said frame captures said key portion. 
     
     
         45 . A photovoltaic module according to  claim 28 , wherein said outward facing groove comprises a locking portion stop. 
     
     
         46 . A photovoltaic module according to  claim 45 , wherein said locking portion stop comprises a hard stop adapted to resist rotation of said coupling after connection to said frame. 
     
     
         47 . A photovoltaic module according to  claim 45 , wherein said locking portion stop comprises a hard stop adapted to resist rotation of said coupling with said key portion in a second discrete rotational position. 
     
     
         48 . A photovoltaic module according to  claim 28 , wherein said key portion comprises a radially extending portion adapted to resist rotation of said key portion beyond a predetermined rotational position. 
     
     
         49 . A photovoltaic module according to  claim 28 , wherein said outward facing groove comprises a slot. 
     
     
         50 . A photovoltaic module comprising a frame with an outward facing groove and a coupling, wherein:
 said coupling comprises a rotatably engageable key portion having a length along a radially extending portion and a width across said radially extending portion, said length extending substantially longer than said width and aligning with said outward facing groove in an insertion position.   
     
     
         51 . A photovoltaic module according to  claim 50 , wherein said key portion is adapted to rotate about an axis substantially perpendicular to a longest surface of said outward facing groove. 
     
     
         52 . A photovoltaic module according to  claim 50 , wherein said key portion is adapted to rotatably engage said frame essentially about an axis substantially perpendicular to a longest surface of said outward facing groove. 
     
     
         53 . A photovoltaic module according to  claim 50 , wherein said length is approximately 1.2 to 3 times said width. 
     
     
         54 . A photovoltaic module according to  claim 50 , wherein said key portion comprises two substantially curved surfaces on opposite corners. 
     
     
         55 . A photovoltaic module according to  claim 54 , wherein said substantially curved surfaces allow clockwise rotation inside said outward facing groove. 
     
     
         56 . A photovoltaic module according to  claim 50 , wherein said length of said key portion in said insertion position is substantially aligned with a length of said outward facing groove. 
     
     
         57 . A photovoltaic module according to  claim 50 , wherein said outward facing groove is adapted to receive said key portion in said insertion position at substantially any point along said outward facing groove. 
     
     
         58 . A photovoltaic module according to  claim 50 , wherein said outward facing groove extends substantially a length of a frame member of said frame. 
     
     
         59 . A photovoltaic module according to  claim 50 , wherein said key portion comprises a locking portion. 
     
     
         60 . A photovoltaic module according to  claim 1 , wherein said outward facing groove comprises a slot.