U.S. patent application number 13/421797 was filed with the patent office on 2012-10-18 for method and apparatus for forming and mounting a photovoltaic array.
This patent application is currently assigned to ZEP SOLAR, INC.. Invention is credited to Hans-Christoph Haenlein, John R. West.
Application Number | 20120260972 13/421797 |
Document ID | / |
Family ID | 43430648 |
Filed Date | 2012-10-18 |
United States Patent
Application |
20120260972 |
Kind Code |
A1 |
West; John R. ; et
al. |
October 18, 2012 |
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.
Inventors: |
West; John R.; (San Rafael,
CA) ; Haenlein; Hans-Christoph; (San Jose,
CA) |
Assignee: |
ZEP SOLAR, INC.
San Rafael
CA
|
Family ID: |
43430648 |
Appl. No.: |
13/421797 |
Filed: |
March 15, 2012 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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13351397 |
Jan 17, 2012 |
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13421797 |
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12594935 |
Oct 6, 2009 |
8109048 |
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13351397 |
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Current U.S.
Class: |
136/251 ;
136/259; 403/345 |
Current CPC
Class: |
F24S 25/20 20180501;
F24S 25/70 20180501; F16B 5/10 20130101; Y10T 403/553 20150115;
Y02B 10/20 20130101; H02S 20/23 20141201; Y02B 10/10 20130101; F24S
2025/6006 20180501; F24S 25/16 20180501; Y02E 10/47 20130101; F24S
25/10 20180501; F24S 25/61 20180501; F24S 25/65 20180501; F24S
25/632 20180501; F24S 25/636 20180501; F24S 25/67 20180501; Y10T
403/70 20150115; Y02B 10/12 20130101; Y02E 10/50 20130101 |
Class at
Publication: |
136/251 ;
136/259; 403/345 |
International
Class: |
H01L 31/05 20060101
H01L031/05; F16B 17/00 20060101 F16B017/00; H01L 31/0203 20060101
H01L031/0203 |
Claims
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.
Description
CROSS REFERENCES
[0001] The present application is a continuation of application
Ser. No. 13/351,397, filed Jan. 17, 2012, which is a continuation
of application Ser. No. 12/594,935 filed Oct. 6, 2009, now U.S.
Pat. No. 8,109,048, issued Feb. 7, 2012. The foregoing applications
are incorporated by reference in their entirety as if fully set
forth herein.
BACKGROUND
[0002] Photovoltaic (PV) modules and related mounting hardware are
well known and in widespread use. The most common mass-produced PV
modules in use today include a laminated portion, or PV laminate,
and a frame portion, and are designed specifically to convert light
into electricity. The PV laminate portion is for encapsulating
solar cells in a substantially flat, weather-tight envelope
comprising a laminated construction of various layers including but
not limited to glass, clear plastic, encapsulant material (like
EVA), active photovoltaic material, interconnecting conductors
between solar cells, and a protective backsheet (like PVF film or
glass). Photovoltaic laminates are commonly manufactured today in
rectilinear shapes like squares, rectangles, triangles, and
trapezoids and, due to their fragile nature, are usually completely
enclosed by a permanent, substantially rigid, glued-on frame
portion which holds and protects the delicate edges of the PV
laminate portion and provides a means of supporting the PV laminate
and attaching it to other objects without damaging the PV laminate.
The combination of the PV laminate portion and the glued-on frame
portion is referred to herein as a PV module or framed PV module.
The present invention relates to integral frames for standard PV
laminates, and to the associated mounting hardware which attaches
to the integral frames for the purpose of securing the PV module to
a roof or support structure.
[0003] U.S. Pat. No. 5,571,338 to Kadonome, et al. discloses a
photovoltaic module comprising a photovoltaic panel having a top
edge and a bottom edge. An exterior frame structure attached to
edges of the photovoltaic panel defines an upwardly open groove
extending along at least the top and bottom edges of the panel to
direct rain water away from the underside of the panel.
[0004] U.S. Pat. No. 7,406,800 to Cinnamon describes an integrated
module frame and racking system for a solar panel. The solar panel
comprises a plurality of solar modules and a plurality of series
couplings or splices (in the form of series couplings) for coupling
the plurality of solar modules together. The plurality of splices
provide a way to make the connected modules mechanically rigid both
during transport to the roof and after mounting for the lifetime of
the system, provide wiring connections between modules, provide an
electrical grounding path for the modules, provide a way to add
modules to the panel, and provide a way to remove or change a
defective module. Connector sockets are provided on the sides of
the modules to simplify the electrical assembly of modules when the
modules are connected together with splices.
[0005] U.S. Patent Application 20070074755 by Eberspacher, et al.
teaches a photovoltaic module with a rigidizing backplane. A solar
cell module includes one or more photovoltaic (PV) cells arranged
in a substantially planar fashion. Each PV cell has a front side
and a back side. The PV cells are adapted to produce an electric
voltage when light is incident upon the front side. A rigid back
plane is attached to the PV cells such that the back plane provides
structural support from the back side. The rigid back plane
includes a structural component having a plurality of voids.
[0006] The foregoing examples of the related art and limitations
related therewith are intended to be illustrative and not
exclusive. Other limitations of the related art will become
apparent to those of skill in the art upon a reading of the
specification and a study of the figures.
SUMMARY OF THE INVENTION
[0007] The method and apparatus for forming and mounting a
photovoltaic (PV) array of this invention provides a PV module
framing and coupling system which 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
following embodiments and aspects thereof are described and
illustrated in conjunction with systems, apparatus, tools, and
methods which are meant to be exemplary and illustrative, not
limiting in scope. In various embodiments, one or more of the
above-described problems have been reduced or eliminated, while
other embodiments are directed to other advantages or
improvements.
[0008] The inventive apparatus may provide a slidable parallel
coupling for securely interlocking the outside surfaces of parallel
frame members together in a side to side arrangement, thereby
enabling the formation of a PV array with improved structural load
distribution. The inventive coupling member 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 inventive apparatus may further
provide a rotating portion and locking portion for coupling to
frame attachment, mounting brackets for direct connection to a
mounting surface, grounding teeth for the automatic creation of a
reliable two axis grounding matrix, and a rapid twist-lock
engagement means for reliably interlocking and aligning PV modules
in the array.
[0009] In addition to the exemplary aspects and embodiments
described above, further aspects and embodiments will become
apparent by reference to the figures and by study of the following
detailed descriptions.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] Demonstrative embodiments are illustrated in referenced
figures and drawings. It is intended that the embodiments and
figures disclosed herein are to be considered illustrative rather
than restrictive.
[0011] FIG. 1 is a perspective view of a PV module with a hybrid,
strut-like frame;
[0012] FIG. 2 is a perspective view of a parallel coupling;
[0013] FIG. 3 is a cross-section cut through two adjacent PV
modules;
[0014] FIG. 4 is a perspective view of two adjacent PV modules
coupled together;
[0015] FIG. 5 is a perspective view of a height adjustable
bracket;
[0016] FIG. 6 is a cross-section cut through two adjacent PV
modules;
[0017] FIG. 7 is a perspective view of building with a PV array
attached to a roof;
[0018] FIG. 8 is a side view of the PV array of FIG. 7 at a larger
scale;
[0019] FIG. 9 shows a typical prior art PV array;
[0020] FIG. 10 is a perspective view of the PV array of FIG. 7
viewed from the back;
[0021] FIG. 11 is a cross-section cut through a PV array just above
the couplings;
[0022] FIG. 12 is a simplified top view of two adjacent rectangular
frames;
[0023] FIGS. 13-14 show generic PV arrays comprising four PV
modules with adjacent frame members;
[0024] FIG. 15 shows a prior art strutless PV array;
[0025] FIG. 16 is a perspective view of a coupling;
[0026] FIGS. 17-18 are front and back side views respectively of a
coupling in a first position;
[0027] FIG. 19 is a perspective view of a coupling;
[0028] FIGS. 20-21 are front and back side views respectively of a
coupling in a second position;
[0029] FIG. 22 is a perspective view of a coupling;
[0030] FIGS. 23-24 are front and back side views respectively of a
coupling in third position;
[0031] FIGS. 25-31 depict a second embodiment of the present
invention;
[0032] FIGS. 32-34 depict a third embodiment of the present
invention;
[0033] FIGS. 35-38 depict a fourth embodiment of the present
invention;
[0034] FIGS. 39-40 are a perspective view and a cross section cut
between two interlocked PV modules;
[0035] FIGS. 41-42 are a cross section cut between two interlocked
PV modules and a perspective view of a coupling;
[0036] FIGS. 43-44 are a perspective view and a cross section cut
between two interlocked PV modules;
[0037] FIGS. 45-46 are a perspective view and a cross section cut
between two interlocked PV modules;
[0038] FIGS. 47-48 are a cross section cut between two interlocked
PV modules and a perspective view respectively for an alternate
embodiment;
[0039] FIGS. 49-50 depict a further alternate embodiment;
[0040] FIGS. 51-52 depict a further alternate embodiment as
installed on an open canopy structure;
[0041] FIGS. 53-54 show an alternate embodiment of a PV array with
a snap-in conduit box; and
[0042] FIG. 55 depicts a perspective view of a further alternate
embodiment of a PV module.
DETAILED DESCRIPTION OF THE INVENTION
[0043] Referring to FIGS. 1 through 55, wherein like reference
numerals refer to like components in the various views, there is
illustrated therein a new and improved framing and mounting system
for photovoltaic arrays, generally denominated 10 herein. While
various terms may have their ordinary meaning or particular meaning
in the art, for ease of understanding there is provided herein,
both below and at other locations in this specification, a
non-limiting explanation as to the minimum scope intended for
understanding of the present specification. Terms may be in
singular or plural or any tense while retaining the same general
meaning Photovoltaic is abbreviated as "PV". PV laminate refers to
an encapsulated group of solar cells. Frame refers to a group of
frame members (typically four for a rectangular-shaped PV module)
which support and provide rigidity to a PV laminate. PV module
refers to a single, one-piece, individually deployable electricity
generating device comprising a PV laminate, a frame, and at least
two output wires. A PV array refers to a group of PV modules which
are deployed together and are a part of the same electricity
generating system. A mounting rail or strut is a structural member
which connects to the bottom of a PV module via the use of a
separate fastener (such as a coupling, bolt, etc.) and which serves
to mechanically link two or more PV modules together, thereby
providing structural support for the modules and also providing a
means for connection to a mounting surface.
First Embodiment
Structure
[0044] FIGS. 1-24 depict a first embodiment of the present
invention. FIG. 1 provides a perspective view of a photovoltaic or
PV module 11 with a hybrid, strut-like frame 12. Each PV module is
made of substantially identical construction. As is typical in the
art, frame 12 comprises four frame members 13 which are assembled
around PV laminate 20 and secured by optional adhesive between
frame members 13 and laminate 20 and frame screws 18U, 18L at the
corners. The complete PV module 11 is typically assembled in this
way at a PV module manufacturing facility; then a plurality of
one-piece PV module assemblies 11 are transported to a particular
job site and mounted to a building or other structure to form a PV
array 10. In other embodiments we contemplate the assembly of
frames 12 around PV laminates 20 at the final installed location.
Thus, the exact location of the manufacturing and assembly steps is
non-critical with regards to proper implementation of the present
invention.
[0045] Hybrid, strut-like frame 12 may include substantially
similar construction on all four sides of PV module 11. Top surface
14 of frame 12 is the surface which faces the same direction as the
cells (not shown) in PV laminate 20. Frame outside surface 16
comprises a multifunction female channel portion or slot 26 for the
purpose of interlocking PV modules 11 together and connecting to a
roof or other mounting surface as will be discussed below. Frames
12 as shown here have the corners cut to allow for a typical butt
joint. In other embodiments the frames are joined at the corners
via a mitre joint. Furthermore, any of the typical methods for
joining framing members at the corners is applicable and covered in
the scope of the present invention. Corners may also be fashioned
to allow insertion of couplings from the corner and to allow
smaller couplings to slide around the corner in a formed array. PV
module 11 further comprises positive 22pos and negative 22neg
output cables with positive 24pos and negative 24neg plugs as are
typical in the art. In other embodiments multi-conductor cables are
utilized. Output cables 22pos, 22neg originate in a rear-mounted
electrical box 21.
[0046] FIG. 2 depicts a perspective view of an interlocking device
or parallel coupling 50a which may be utilized to interlock the
outside surfaces 16 of two adjacent PV module frames 12 via a
twist-lock action. This first embodiment contemplates a one-piece
parallel coupling 50a comprising a rotating portion 100 with shaft
portions 102A, 102B protruding from each side. The end of shaft
portion 102A comprises a first key or locking portion 104A, and the
end of shaft portion 102B comprises a second key or locking portion
104B. Both locking portions 104A, 104B rotate with the shaft
portions 102A, 102B upon rotation of rotating portion 100 with a
wrench.
[0047] Rotating portion 100 further comprises an optional top
spring 106U and bottom spring 106L to help account for variations
in material and assembly tolerances, to mitigate thermal expansion
and contraction variance, and to provide a force which resists the
unlocking of two interlocked PV modules 11. Bores 110U and 110L
(not viewable here) in rotating portion 100 are provided to house
and structurally support springs 106U, 106L respectively. Springs
106U, 106L are shown here as cylindrical springs and may be made
from spring steel or other suitable spring material. Other
embodiments contemplate springs of other types and shapes, and
still other embodiments provide coupling 50a without springs since
frame 12 under compression provides some spring force. For example,
disc washers, wave washers, star washers, finger springs, spiral
springs, polyurethane springs, and others are all suitable for use
with the present embodiment under discussion. Rotating portion 100
comprises four flat faces 116 so that rotating portion 100 can be
easily turned with a typical wrench from above. One skilled in the
art will recognize that the number of flat faces could vary and
rotating portion 100 could be simply rounded, slotted, bored, or
knurled depending on the type of wrench which is utilized. Shaft
portions 102A, 102B further comprise optional reduced diameter
portions 114A, 114B to help guide and hold a free PV module 11
which is being moved into position for coupling. Rotating portion
100 (except for springs 106U, 106L), shaft portions 102A, 102B, and
locking portions 104A, 104B may be machined from a single piece of
solid metal, such as steel or aluminum. In another embodiment
rotating portion 100 may be made of a light-weight material such as
plastic. However, one skilled in the art will recognize that
multiple components could be assembled together and various
materials could be used to form the various portions of coupling
50a as described herein.
[0048] Expanding the discussion now to further include FIG. 3,
which depicts a cross-section cut through two adjacent PV modules
11A, 11B which are coupled together with a coupling 50a, it can be
seen that first locking portion 104A may be specially shaped to be
the first of the two locking portions 104A, 104B which is inserted
into a first slot 26A of PV module 11A. Locking portion 104A may be
provided with curved surfaces 118U, 118L on opposite corners which
allow locking portion 104A to be rotated in a clockwise manner
inside of slot 26A until locking portion stops 120AU, 120AL contact
upper 122AU and lower 122AL inside surfaces of slot 26A
respectively. With reference to FIGS. 16-24, which will be
discussed in more detail below, one skilled in the art will
recognize that the width of locking portion 104A is slightly less
than the height A of openings 27A, 27B in slots 26A, 26B, while the
length is approximately equal to the height B inside of slot 26A.
Therefore locking portion 104A may be inserted when it is oriented
in a first position 91 and captured behind male features or flanges
108AU, 108AL when it is rotated clockwise. After approximately 90
degrees of clockwise rotation, when locking portion stops 120AU,
120AL are reached coupling 50a is said to be in a third position 93
(see below for discussion of an intermediate second position
92).
[0049] Accordingly, second locking portion 104B may be specially
shaped to be the second of the two locking portions 104B, 104A to
be inserted into a second slot 26B in PV module 11B. This first
embodiment contemplates a shape for locking portion 104B which is
capable of passing between male features or flanges 108BU and 108BL
for approximately the first 45 degrees of clockwise rotation of
coupling 50a. Thus the intermediate position of approximately 45
degrees of clockwise rotation is said to be the second position 92.
The shape of locking portion 104B is similar to locking portion
104A except that material has been removed in the clearance zones
124U, 124L directly opposite curved surfaces 118U, 118L on locking
portion 104A. Thus, orientation of coupling 50a in first position
91 and insertion of locking portion 104A into slot 26A followed by
a rotation to second position 92 results in locking portion 104A
being captured by slot 26A and locking portion 104B being correctly
oriented for insertion into slot 26B. Furthermore, insertion of
locking portion 104B into slot 26B followed by an additional
rotation of approximately 45 degrees clockwise to third position 93
results in locking portion 104B being captured by slot 26B.
Rotation ceases when locking portion stops 120AU, 120AL contact
surfaces 122AU, 122AL inside slot 26A and locking portion stops
120BU, 120BL contact surfaces 122BU, 122BL inside slot 26B, and at
this point the outside surfaces 16A and 16B of PV modules 11A and
11B are said to be coupled or interlocked together (these two terms
are used interchangeably throughout this document). Other
embodiments contemplate a number of variations on the locking
portions 104A, 104B and the slots 26A, 26B, all of which are within
the scope of the present invention. For example, some embodiments
may utilize locking portions 104A, 104B which are identical in
shape but simply rotated at different angles from each other
relative to shaft portions 102A, 102B. Such embodiments are still
capable of providing a solid interlock but do not allow removal of
a single module from the middle of a completely installed PV array
10 since first position 91 can only be reached when locking portion
104B is not inside slot 26B. Other embodiments include locking
portions which are shaped for different angles of rotation other
than 45 and 90 as discussed above, while others have locking
portions which are shaped for counter-clockwise rotation.
[0050] Locking portions 104A, 104B further comprise tapered
surfaces 105AU, 105AL, 105BU, and 105BL to guide them into position
as coupling 50a is rotated and raised teeth 112AU, 112AL, 112BU,
and 112BL for cutting into frame 12 and ensuring solid electrical
ground contact between two adjacent PV modules 11 when they are
coupled together. Teeth 112AU, 112AL, 112BU, 112BL also provide
structural support by counteracting forces which tend to slide
coupling 50a lengthwise in slots 26A, 26B. In other embodiments
teeth 112 are provided in different locations than those shown
here, and in still other embodiments teeth 112 are replaced by a
separate grounding washer, such as a star washer, which is
positioned between a portion of coupling 50a and frame 12.
[0051] As shown in FIG. 3, slots 26A, 26B from two adjacent,
interlocked modules 11A, 1 lB comprise openings 27A, 27B which
allow insertion of couplings 50a in a direction which may be
substantially parallel with the plane of laminates 20A, 20B and
substantially perpendicular with outside surfaces 16A, 16B. Flanges
108AU, 108AL, 108BU, 108BL, which are located near openings 27A,
27B create (by virtue of their position) inside surfaces 109AU,
109AL, 109BU, 109BL of slots 26A, 26B which are available for use
by couplings 50a and brackets 132 (see below) as a bearing surface.
Inside surfaces are shown here as being substantially perpendicular
to PV laminate 20. However, other embodiments provide sloped and
curved surfaces 109AU, 109AL, 109BU, 109BL.
[0052] FIG. 3 further reveals frame inside surfaces 17A, 17B; frame
bottom surfaces 15A, 15B; frame screw holes 19AU, 19AL, 19BU, 19BL
for frame screws 18B, 18U; and frame recesses 126A, 126B for
capturing PV laminates 20A, 20B. This view also shows how
substantially constant spacing between PV modules 11 in an array 10
is automatically determined by the width of rotating portion 100,
with minor material and assembly tolerance issues being allowed by
variable compression amounts on springs 106U, 106L. For example,
manufacturing of a perfectly square PV module 11 is very difficult.
Therefore it is common for PV modules to have widths and lengths
that vary by up to 1/8''. In prior art systems this variance is not
accounted for. The springs 106U, 106L as shown here provide a
degree of compliance that helps to mitigate the compounding of
tolerance errors and therefore major problems with proper alignment
during installation.
[0053] FIG. 4 depicts a perspective view of two adjacent PV modules
11A, 11B which are coupled together with two couplings 50a. Since
slots 26A, 26B may run substantially the whole length of frames
12A, 12B, couplings 50a may be located at substantially any point
along the length. Given the high strength connection provided, in
practice one to three couplings per seam between two PV modules is
typically adequate. At a corner 130 of each PV module 11 the
flanges 108AU, 108AL, 108BU, 108BL are cut off thus allowing
coupling 50a to easily slide from the seam between one set of PV
modules 11 over to the seam between an adjacent pair of PV modules
11 when coupling 50a is in first position 91 as discussed
above.
[0054] Referring now to FIGS. 5-6, FIG. 5 depicts a perspective
view of a height adjustable bracket 132 which is suitable for
connection to a PV module 11 of the first embodiment of the present
invention, and FIG. 6 shows a cross-section cut through two
adjacent PV modules 11A, 11B which are coupled together with a
coupling 50a (not picture here for clarity, see FIG. 3). An
L-shaped bracket 132 comprises a z-axis or vertical adjustment slot
140 and a y-axis adjustment slot 142 (coordinate system based on
plane of mounting surface, see FIG. 7). A channel bolt 136 with
bolt head 137, which is threaded into a channel nut 134, is
utilized to attach bracket 132 to outside surface 16B of frame 12B.
Channel nut 134 is shaped to fit inside slot 26B and to be captured
behind flanges 108BU, 108BL. This embodiment contemplates a simple
rectangular shape for channel nut 134 with nut 134 being inserted
at corner 130 and slid into position. Threading bolt 136 into nut
134, sliding bracket 132 between bolt head 137 and frame outside
surface 16B, and then tightening bolt 136 serves to pull nut 134
solidly against flanges 108BU, 108BL thereby rigidly securing
bracket 132 to frame 12B. And since slot 26B runs substantially the
whole length of frame 12B, bracket 132 can be attached to
substantially any point along the length, which will be referred to
as the x-axis direction. Therefore, slot 26B along with slot 140
and slot 142 allows for 3 dimensional adjustability of bracket 132,
enabling greatly simplified installation via much easier lining up
of brackets 132 with rafters (which typically run in the y-axis
direction) and much easier leveling and aligning of PV modules
within arrayl O. Lag screw 138 provides a means of directly
securing bracket 132, and therefore array 10, to a mounting surface
144, such as a roof without any other support structure as is
typical in prior art systems.
[0055] Please note that while FIG. 6 shows a connection of bracket
132 to right frame 12B, it can be connected to any outside surface
16, and furthermore it can be reversed so that lag screw 138 is
positioned beneath the PV module 11 to which it is connected. In
other embodiments nut 134 comprises a rectangular shape with two
opposing rounded corners, similar to locking portion 104B, so that
it can be inserted into slot 26B from any point along frame 12B and
then twisted 90 degrees to tuck behind flanges 108BU, 108BL. In
still other embodiments nut 134 is a standard hexagonal-shaped
nut.
[0056] One alternate embodiment removes lower flanges 108AL, 108BL
from slots 26A, 26B and the lower portions of locking portions
104A, 104B resulting in a one-sided locking action instead two as
with the first embodiment.
First Embodiment
Basic Operation
[0057] Referring to FIGS. 7-8 and FIGS. 10-11, a PV array 10
according to the first embodiment of the present invention is shown
installed on the roof of a building 146. FIG. 7 depicts a
perspective view of building 146 with PV array 10 shown attached to
a roof 144R which serves as a suitable mounting surface 144. Roof
rafters 148 are just beneath the top surface of the roof and are
shown as dashed lines. Brackets 132 can be seen in this view along
the front of PV array 10. Brackets 132 are oriented such that lag
screws 138 are hidden under PV modules. Brackets 132 can be seen
attached to slots 26 on the outside surface 16 of the lowest row of
three PV modules 11, one bracket 132 per PV module 11. Brackets 132
have been adjusted in their respective slots 26 in the x-axis
direction such that each bracket 132 lines up with a rafter 148.
Since lining up of brackets 132 with rafters 148 is only required
with certain types of roofs and mounting surfaces, other
embodiments provide brackets 132 which are not lined up with
rafters, but rather attach directly to the mounting surface at any
desired point. In still other embodiments, brackets 132 are
adjusted in the x and y directions to line up with ground mounted
structures, pier blocks, concrete posts, and specialized mounting
hardware such as roof jacks, mounting posts, mounting jacks, tile
brackets, specialized brackets, and stand-offs. Since the inventive
system provides three dimensional adjustability, it can be
connected to almost any suitable mounting surface.
[0058] FIG. 8 shows a side view of the same PV array 10 from FIG. 7
at a larger scale. This figure helps to clarify the fact that PV
array 10 is connected to roof 144R without the use of strut or
other supports. Brackets 132 connect frames 12 directly to roof
144R, and couplings 50a interlock PV modules 11 together. In
contrast, FIG. 9 shows a typical prior art PV array 10PA without
the benefit of an interlocking system as disclosed herein. PV
modules 11PA are first linked together by struts 131PA. Struts
131PA are then attached to a mounting surface (not shown) via
brackets 132PA. As can be seen here strut 131PA is a device which
is at least as wide as two PV modules 11PA and is designed to
support the opposing sides of at least two PV modules 11PA. A
coupling, on the other hand, only joins PV modules together at the
seam between the two modules and therefore is not wider than a
single module. The fact that struts 131PA are designed to span
between modules 11PA means that a lot of extra material is
required. The additional expense and installation time required to
utilize strut 131PA is a significant drawback to prior art
systems.
[0059] FIG. 10 shows a perspective view of the same PV array 10
from FIG. 7 except that array 10 is being viewed from the back
(exactly 180 degrees around from the FIG. 7 view) with building 146
removed to reveal the back side of PV array 10. In this view it is
now evident that a row of three brackets 132 is located along every
horizontal seam 150 between PV modules 11 and along the top 154 and
bottom 156 edges of array 10. This method of relatively evenly
distributing brackets 132 across array 10 is not possible with
prior art strutless systems which utilize series couplings (see
discussion below).
[0060] FIG. 11 shows a cross-section cut through PV array 10 (from
FIG. 7) just above couplings 50a and looking perpendicular to array
10 thereby revealing the locations of couplings 50a and brackets
132 (roofing material not shown beneath array 10 for clarity).
Couplings 50a are shown interlocking all PV modules 11 in array 10
at all horizontal 150 and vertical 152 seams between PV modules 11.
In other embodiments couplings 50a are only utilized on either
horizontal seams 150 or vertical seams 152. The arrangement of
couplings as shown here creates a double structure or parallel
interlock support system 160 for array 10 along both the x and
y-axes as will be discussed below. Each frame 12 is referred to as
a hybrid, strut-like frame because, unlike most prior art systems,
it performs the following basic functions which are normally shared
between a PV frame and a strut or similar structural support
system: (a) holding and protecting the edges of PV laminate 20; (b)
interconnecting modules 11 together with a structural support
system (in order to increase structural integrity and minimize the
number of required connection points to mounting surface 144); and
(c) providing a means for attaching array 10 to mounting surface
144 via foot-type or bracket members.
First Embodiment
Series and Parallel Coupling Theory
[0061] FIG. 12 provides a simplified top view of two adjacent
rectangular frames A and B. Lines C.sub.1, C.sub.2, C.sub.3, and
C.sub.4 represent places along the seam between the two frames A
and B where couplings can theoretically be placed. Couplings which
connect at lines C.sub.1 and C.sub.2 are referred to as parallel
couplings since a union of frames A and B at these points results
in frames A and B being interlocked in parallel. It follows then
that any point along the seam between A and B is theoretically
capable of receiving a parallel coupling. However, the corner
points K.sub.1 and K.sub.2 are special cases since prior art slots
in the outside surfaces of frames do not extend all the way to the
corner on both sides of a pair of orthogonal frame members. This
problem arises from the nature of the aluminum extrusion process
(which is how most PV frames are manufactured) and prevents the
sliding of parallel couplings all the way to the end on at least
two sides of a rectangular PV module. The corners are also a
special case for a second reason. The corners K.sub.1 and K.sub.2
are the only places around the perimeter where a coupling can be
inserted into the outside surface of a first frame member B.sub.4
and continue through into a second frame member B.sub.3 which is
around the corner from the point of insertion. Thus, lines C.sub.3
and C.sub.4 are shown extending from parallel frame members
A.sub.2, B.sub.4 into the orthogonal frame members B.sub.1, B.sub.3
and A.sub.1, A.sub.3. Since the ability to run a coupling into an
orthogonal frame member clearly enhances the structural properties
(z-axis loads can be distributed over a larger area), prior art
couplings fall into two basic categories: parallel couplings which
are optimized to connect to the side of a frame member
substantially anywhere along the whole length of the member and
series couplings which are optimized for the special case of
connecting to the ends of frame members at the corner points
K.sub.1, K.sub.2. Series couplings are so named because they link
two frame members, such as A.sub.3 and B.sub.3, end to end.
[0062] In order to understand the operation of PV array 10 of the
first embodiment, it is important to first understand how the
forces that are presented to PV array 10 are distributed across it.
Forces can act over the entire surface, such a wind pressure, or
forces can be highly localized, such as someone stepping on it. In
either case, these forces must find their way to the roof 144R or
mounting surface 144 via brackets 132 that mount the PV system, and
these brackets 132 may be some distance away from the point or area
of application of the force. In many cases the force must pass
across PV modules and the transitions between them in order to make
it to mounting surface 144. A coupling device for interlocking
frame members 13 provides an opportunity to further support frame
members 13 by locking it to adjacent frame members 13. For an
individual PV module 11 each frame member 13 acts as a separate
structural entity which is supported by PV laminate 20 and
connected to orthogonal frame members at the corner joints. Even in
a hypothetical case of a framed PV laminate which comprises a frame
constructed out of a single piece of material (no such example
exists to our knowledge), each side of the frame is still a
separate structural entity since the sides are mostly separated by
the laminate and only connected by a small portion in the corners.
Thus, it is important to discuss which frame member and where on
the frame member a particular coupling is connected if one wants to
understand the structural properties of the coupling. Assuming that
PV module 11 comprises substantially straight frame members 13,
then the possible shapes (in a top view) for flat-plate PV module
11 are a triangle, rectangle, pentagon, hexagon, etc. All such
shapes are suitable for use with the present invention.
[0063] FIGS. 13-14 show generic PV arrays 10P and 10S, comprising
four PV modules 11A, 11B, 11C, 11D with adjacent frame members
13A1, 13B1; 13A2, 13C2; 13B2, 13D2; 13C1, 13D1 respectively. These
two figures demonstrate the two basic types of couplings which are
possible in a rectangular array: parallel couplings 50 and series
couplings 62. When straight-sided PV modules 11A, 11B, 11C, 11D are
assembled to form substantially rectangular PV arrays 10P and 10S,
the result is a plurality of frame members 13 which are immediately
adjacent to each other (within arrays 10P, 10S) and a plurality of
frame members 13 around the perimeter of arrays 10P, 10S. FIG. 13
shows parallel couplings 50 that each connect two adjacent and
substantially parallel frame members 13 side to side. FIG. 14 shows
series couplings 62 that each connect two substantially collinear
frame members 13 end to end.
[0064] As shown in FIG. 13, parallel couplings 50 allow a force
F.sub.1 applied to PV module 11B to be distributed between the PV
modules immediately adjacent to it, 11A and 11D, along paths
P.sub.1, P.sub.2, P.sub.3, as well as out to the more remote PV
module 11C along paths P.sub.4 and P.sub.5. This distribution of
forces is enabled since parallel couplings 50 allow both the
connection of frame members 13 end to end and side to side. For
example, frame members 13B1 and 13A1 are interlocked in addition to
the orthogonal pair of frame members 13B2 and 13D2. This connection
of orthogonal pairs of frame members 13 enables the connection of
each row of PV modules 11A, 11C, to the adjacent row 11B, 11D and
allows force F1 to be distributed across all the PV modules in
array 10P, thus strengthening the entire frame structure supporting
PV laminates 20. However, series couplings 62, as shown in FIG. 14,
will only allow forces to be distributed down the rows 11A, 11C and
11B, 11D which are attached in this way. The same force F.sub.1
presented to module 11B in this case can only take paths P.sub.10
and P.sub.11, thus preventing the distribution of loads to PV
modules 11A, 11C.
[0065] While series couplings 62, as are known in the prior art,
are clearly less advantageous than parallel couplings, some
embodiments of the present invention, as will be discussed below,
provide a means for adding a series coupling portion to a parallel
coupling thereby creating a series-parallel coupling. There are
distinct advantages to such a hybrid coupling since in theory a
series coupling may provide more opportunity for enhancing the
z-axis strength of frame 12 (though such potential is not realized
in prior art couplings).
[0066] Parallel interlock support system 160 operates as follows.
The specialized slot 26 allows couplings 50a to securely connect
the sides of each immediately adjacent and parallel pair of frame
members 13. It is common for installation technicians to step on a
PV laminate 20 during installation. This action provides a
localized load such as would generate force F.sub.1. In prior art
strutless systems, force F.sub.1 is translated to the frames which
are nearest to the point of loading, and each frame member 13 is
acting mostly independently since there are no securely connected
additional supporting members nearby. In the first embodiment of
the present invention, however, force F.sub.1 presented to the top
of PV laminate 20 is shared by frame 12 which surrounds PV laminate
20 as well as the four frame members 13 which are coupled to the
loaded PV laminate 20. Thus, it can be seen that a support grid is
created by the simple and rapid connection of couplings 50a to
adjacent frames 12. This grid is evenly distributed in the x and y
directions throughout array 20, and the doubled support members run
beneath the edges of each PV laminate 20. The result is a PV array
10 which can be mounted to a roof or other mounting surface 144
without the need for costly and heavy strut (or other structural
members). Furthermore, the increased spanning capabilities provided
by the parallel interlock support structure 160 significantly
reduce the number of connection points (and therefore brackets 132)
for a given size array 10 on a given mounting surface 144 as
compared to prior art strutless systems.
[0067] FIG. 15 shows a prior art strutless PV array 210PA with PV
modules 211PA, brackets 232PA, and series couplings 250PA. As
discussed above, series couplings must be connected at the corners
and therefore they cannot be used to connect two adjacent rows
together. Thus, brackets between rows must be doubled up (as shown)
or specialized (and difficult to install) double brackets must be
utilized. And, as mentioned above, the total number of brackets
232PA is also increased relative to the inventive device of the
first embodiment because spans between brackets 232A cannot be as
long.
First Embodiment
Coupling Modes
[0068] The unique structure of the framing and coupling systems of
the first embodiment enables three distinct modes of operation:
positioning mode, locked mode, and sliding mode. In the first
embodiment these different modes may be easily accessed via
rotation of coupling 50a into one of the three discrete positions
91, 92, 93 as discussed above. Other embodiments access these modes
via different means as will be discussed below.
[0069] Positioning mode is primarily utilized during installation
and removal of PV modules 11 in PV array 10. Positioning mode
secures coupling 50a to one PV module 11 of a pair of PV modules 11
to be interlocked. Since the positioning of PV modules can be
difficult, particularly on sloped roofs, positioning mode insures
that coupling 50a will stay in position as the two modules are
guided together. Thus, in positioning mode coupling 50a is either
firmly secured or loosely attached to one PV module 11.
[0070] Locked mode is the mode that all couplings are left in once
array 10 is fully installed. Locked mode securely interlocks two
adjacent PV modules 11 together thereby forming a parallel
interlock support system 160 as discussed above. In locked mode
coupling 50a is firmly secured to two adjacent PV modules. This
mode also automatically grounds the two interlocked modules 11 to
each other and forces them into proper alignment and spacing. The
automatic grounding feature of the first embodiment of the present
invention provides a substantial improvement over prior art systems
because PV modules are electrically grounded to each other both
within rows of modules 11 and between rows. Thus a complete x-y
grounding matrix results so that only one ground wire needs to be
run from PV array 10 to the grounding equipment for the site.
[0071] Sliding mode is primarily used during installation and
removal of PV modules 11 in array 10. Sliding mode partially
decouples two interlocked PV modules so that coupling 50a may be
repositioned or slid all the way down slot 26 and over into slots
26 for an adjacent PV module pair in array 10. This allows removal
of an individual PV module 11 that is surrounded by adjacent PV
modules 11 installed on all sides. Thus in sliding mode coupling
50a is loosely attached to two adjacent PV modules. Prior art
systems do not teach or imply a PV array coupling and framing
system capable of achieving all three of these coupling modes
(positioning, sliding, and locked).
First Embodiment
Coupling Process
[0072] FIGS. 16, 19, and 22 depict a perspective view of coupling
50a in each of its three discrete positions 91, 92, 93 respectively
as it is utilized to interlock two adjacent frames 12A, 12B
together (only a portion of frames 12A, 12B are shown so that
locking portions 104A, 104B are revealed). Please note that since
coupling 50a may be installed in either frame first, FIGS. 16, 19,
and 22 show frames 12A, and 12B in opposite positions than in FIG.
3. FIGS. 17-18 show front and back side views respectively of
coupling 50a in first position 91. FIGS. 20-21 show front and back
side views respectively of coupling 50a in second position 92.
FIGS. 23-24 show front and back side views respectively of coupling
50a in third position 93. The following description also references
FIGS. 2-3 since some parts are easier to see in closer views.
[0073] The process of interlocking two adjacent frames 12A, 12B is
as follows. First, coupling 50a is oriented in first position 91,
which aligns the length of locking portion 104A with the length of
slot 26A, then inserted at substantially any point along frame 12A
into slot 26A. While inserting, the direction of travel is
substantially parallel with the plane of laminate 20A and
substantially perpendicular to the length of slot 26A. Coupling 50a
is inserted until locking portion 104A hits the back of slot 26A or
rotating portion 100 contacts outside surface 16A of frame 12A.
FIG. 16 shows coupling 50a in first position 91 and fully inserted.
For convenience, we contemplate alignment of rotating portion flat
faces 116 at 45 degrees to the plane of laminate 20 when in first
position 91: this way the corner point of rotating portion 100 is
pointing straight up and is therefore easy to align by eye. Of
course other orientations for flat faces 116 will work just as
well. One skilled in the art will recognize that springs 106U, 106L
are oriented such that they are not touching frames 12 in first
position 91 (since they line up with opening 27A, 27B of slot 26A,
26B). Therefore, a return to first position 91, even after the
complete array 10 has been installed, will enable sliding mode
since it is not locked onto either frame and since springs 106U,
106L are not compressed.
[0074] The second step is to rotate coupling 50a into second
position 92 in order to enable positioning mode as is depicted in
FIGS. 19-21. Though lighter duty springs may be used, we
contemplate the use of relatively stiff springs for springs 106U,
106L since movement of the modules 11 in array 10 may be
undesirable once the installation is complete. Springs with a full
deflection rating of 100 to 500 pounds may work well, but other
spring rates are also suitable. Thus, in order to move coupling 50a
from first position 91 to second position 92, a wrench is applied
to rotating portion 100 to rotate it approximately 45 degrees
clockwise. In this position locking portion 104A is locked onto
frame 12A and springs 106U, 106L are partially compressed. Please
note that during the first part of the 45 degree rotation from
first position 91 to second position 92, tapered surfaces 105AU,
105AL engage with flanges 108AU, 108AL to pull the locking portion
further into the slot. By guiding locking portion 104A into place,
tapered surfaces 105AU, 105AL also enable an increased range of
acceptance angles for initial alignment of locking portion 104A and
therefore increase the flexibility and ease of use of coupling 50a
since it doesn't have to be "dead on" in order to rotate. As
coupling 50a is being rotated from first 91 to second 92 position,
teeth 112 AU, 112AL begin to bite into flanges 108AU, 108AL when
the end of tapered surfaces 105AU, 105AL is reached. From this
point on through the rest of the full 90 degree throw, the surfaces
of locking portion 104A which are in contact with flanges 108AU,
108AL remain relatively parallel with flanges 108AU, 108AL.
Therefore, the force applied by springs 106U, 106L effectively
squeezes coupling 50a about flanges 108AU, 108AL and it is held in
a stable position if the wrench is removed from rotating portion
100. Thus, second position 92, as shown in FIG. 19, is a stable
discrete position with coupling 50a attached only to frame 12A. The
second frame 12B can now be moved into or out of position without
knocking coupling 50a out of position. Unlike some prior art
systems which require both PV modules 11A, 11B to be in place and
aligned before a coupling can be connected, the inventive device of
the first embodiment allows free positioning of modules with
coupling 50a connected to one of them in positioning mode. For
example, in some cases it may be advantageous to insert couplings
into some PV modules 11 on the ground before taking them up to a
roof to be mounted. In other cases couplings 50a may be locked onto
PV modules 11 at the factory prior to shipping. Also, when
interlocking a free PV module to an already mounted PV module,
coupling 50a may be attached to either the free PV module or the
already mounted PV module. Positioning mode is enabled since
locking portion 104B is shaped such that it only begins to lock
itself onto frame 12B when coupling 50a is being rotated from
second position 92 to third position 93.
[0075] FIGS. 22-24 depict coupling 50a in third position 93,
securely attached to frames 12A, 12B in locked mode. The process of
rotating from second position 92 to third position 93 is basically
the same as that from first 91 to second 92. A wrench is used to
rotate rotating portion 100. Tapered surfaces 105BU, 105BL guide
locking portion 104B into slot 26B and teeth 112BU, 112BL begin to
bite into flanges 108BU, 108BL when the end of tapered surfaces
105BU, 105BL is reached. Arrival at third position 93 is signaled
by locking portion stops 120AU, 120AL contacting upper 122AU and
lower 122AL inside surfaces of slot 26A respectively and 120BU,
120BL contacting upper 122BU and lower 122BL inside surfaces of
slot 26B respectively. Locking portion stops 120AU, 120AL, 120BU,
120BL provide a solid, hard stop which prevents rotation of the
wrench any further, therefore significantly simplifying the
installation procedure and increasing the quality thereof by
eliminating the possibility of over or under-torqued bolts.
[0076] The above discussion of the coupling process clearly shows
how a rotation of coupling 50a from first position 91 to third
position 93 causes locking portion 104A to bear against inside
surfaces 109AU, 109AL of slot 26A and rotating portion 100 via
springs 106U, 106L to bear against an opposing frame surface,
outside surface 16A. Since springs 106U, 106L act to transfer
forces from rotating portion 100 to frames 12A, 12B, they are also
referred to as force transfer portions. Likewise locking portion
104B bears against inside surfaces 109BU, 109BL of slot 26B and
rotating portion 100 via springs 106U, 106L bears against an
opposing frame surface, outside surface 16B. Thus it is clear that
coupling 50a securely interlocks PV modules 11A and 11B together by
bearing against opposing surfaces on each frame 12A, 12B upon
rotation of rotating portion 100.
[0077] Please note that this method of interlocking is quite
different from most prior art systems which interlock adjacent PV
modules by means of a coupling that bears against the frame and a
strut, a mounting rail, a bracket, or other structural member which
is sandwiched between opposite ends of the coupling. This basic
structural difference enables the forming and mounting of PV arrays
10 without requiring the use of separate structural support members
(such as strut, mounting rails, and the like) which attach directly
to and span between multiple PV modules in a formed PV array
10.
First Embodiment
Installation Methods
[0078] Referring to FIGS. 7-8 and FIGS. 10-11, the basic steps
involved in the forming and mounting of PV array 10 according to
the second embodiment of the present invention may be as
follows:
[0079] Step 1: Secure a first PV module 11 to roof 144R with at
least one bracket 132.
[0080] Step 2: Interlock a second PV module 11 to the first PV
module 11 with at least one parallel coupling 50a which interlocks
the sides of two adjacent frame members 13 together in
parallel.
[0081] Step 3: Attach second PV module 11 to roof 144R with at
least one bracket 132.
[0082] Step 4: Repeat steps 2 and 3 for all remaining PV modules 11
in PV array 10, successively interlocking each new PV module 11 to
the side of a mounted PV module 11 and attaching at least one
bracket 132 to each module.
[0083] The details of Step 2 above may be as follows: insert
coupling 50a into slot 26 of the mounted PV module 11, rotate
rotating portion 100 to second position 92 with a wrench thereby
enabling positioning mode, mate second PV module 11 with coupling
50a, rotate coupling 50a to third position 93 thereby enabling
locked mode. The wrench is operated from above by sliding wrench
between the two modules 11 (which may be as close as approximately
1/4'' apart). Alternately coupling 50a may be placed on the free
module 11 for positioning mode instead of the mounted module
11.
[0084] The details of Step 3 may be as follows: install bracket
flashing or mounting plate, loosely install bracket 132 on mounting
plate, attach bracket 132 to PV module 11 at any point along the
side where it lines up with required bracket placement, secure
bracket 132 to mounting plate. Since there are many types of
mounting surfaces, there, of course numerous ways that brackets 132
can be installed. Thus, the inventive system of the first
embodiment provides slot 26 and height adjustable bracket 132 in
order to provide maximum flexibility in adapting to almost any
mounting situation.
[0085] Parallel couplings 50a may be used at substantially any
point in any horizontal 150 or vertical 152 seam between adjacent
PV modules. Each seam 150, 152 may include one, multiple, or no
couplings 50a depending on the installation requirements.
Substantially all brackets 132 may be attached by sliding channel
nuts 134 into slots 26 from the end, aligning with bracket 132, and
screwing bolt 136 into channel nut 134 to capture bracket 132.
[0086] Final tightening of each coupling 50a and bracket 132
connection is flexible and does not necessarily coincide with
initial placement in array 10 of that module 11. This flexibility
allows PV modules 11 to be temporarily positioned in the array
while others are positioned or while wiring or other installation
issues are handled. Since all couplings 50a are capable of being
tightened from the top, PV modules 11 can be moved into locked mode
at any time. One skilled in the art will recognize that the 2-axis
nature of the couplings in the embodiment under discussion means
that PV modules 11 can be installed in any order and in
substantially any shape for PV array 10 as long as each new PV
module 11 is interlocked to a mounted PV module 11, and all new
modules 11 are added to a mounted module which has a portion of a
frame member 13 free (not already interlocked to another PV
module). It is possible, for example, to mount PV modules in a
generally rectangular shape, but then leave out modules 11 in the
middle to avoid vents or other obstructions. In another example,
each row of PV modules 11 may be displaced by a specific amount for
architectural reasons or to match a roof line.
[0087] If a module 11 needs to be removed from the middle of a
formed array for servicing, the required steps may be as follows.
First, move all couplings 50a which are connected to it back into
first position 91 with a wrench from above thereby enabling sliding
mode for each. Then slide all loosened couplings 50a over to
neighboring modules 11. In some cases a bracket 132 may prevent
sliding in one direction but not both. Brackets 132 are typically
installed with one per module, so there is normally at least one
direction to slide. If two brackets 132 are required, then
couplings 50a are not used in between the two brackets 132. Next,
loosen bolts 136 which connect brackets 132 to frames 12 on the
effected module 11 and lift it straight up and out of array 10
(disconnecting wires before moving it too far). In this way an
individual PV module 11 that is installed in the middle of array 10
may be removed without requiring the removal of the surrounding
modules 11, thereby substantially saving time during
troubleshooting and maintenance as compared to prior art
systems.
[0088] In another embodiment PV modules 11 comprise non-rectangular
shapes such as triangular or hexagonal and the coupling system
works in the same manner as described above. In another embodiment
PV modules 11 are small enough to not require one bracket 132 per
module. In this embodiment multiple modules are interlocked
together and then one of the group is attached to roof 144R with
bracket 132. In yet another embodiment PV array 10 is mounted to a
ground-mounted rack system instead of roof 144R with no change in
the basic installation method outlined above except that brackets
132 are attached to the rack instead of roof 144R. In still another
embodiment groups of standard-sized PV modules 11 are interlocked
together via couplings 50a on the ground and then hoisted to a roof
where brackets 132 are used to secure them in place.
First Embodiment
Advantages
[0089] The first embodiment of the present invention provides
numerous advantages over prior art systems. Inventive features of
the present apparatus include, but are not limited to the
following:
[0090] Parallel coupling action--parallel coupling is attachable to
substantially the whole length of all four sides of a PV module and
securely locks the outside surfaces of parallel frame members
together in a side to side arrangement, thereby increasing the
structural performance of the PV array.
[0091] Three mode design--Parallel coupling is shiftable with a
wrench into three modes of operation: positioning mode, sliding
mode, and locked mode. A positive stop is provided when locked mode
is reached.
[0092] Locking portion--Parallel coupling provides two specially
shaped locking portions which are insertable into slots on the
outside surfaces of adjacent frame members. Locking portions enable
discrete positions of device and provide a positive stop for locked
position.
[0093] Dual bearing action--Parallel coupling interlocks adjacent
frame members together by bearing against opposing surfaces on each
frame upon rotation of a rotating portion. Locking portion bears
against an inside surface of the slot and the coupling bears
against an opposing surface.
[0094] Twist-lock action--Parallel coupling provides a rotating
portion which shifts from an unlocked position to a locked position
in approximately 90 degrees of rotation.
[0095] Top accessible--Parallel coupling is accessible from the top
even after PV array has been formed. Coupling can be rotated with a
wrench from above to shift from locked mode to sliding mode so that
coupling can be slid into the slots of neighboring PV modules. In
this way a single PV module can be removed from the middle of a
formed PV array.
[0096] One-piece--Parallel coupling is deployable in the field as a
one-piece unit.
[0097] Automatic alignment--Parallel coupling forces interlocked PV
modules into alignment along both the x and y axes of PV array.
Spacing between modules and height of modules is automatically set
upon rotation into locked mode.
[0098] Automatic grounding--Rotation of parallel coupling into
locked mode causes integral teeth to bite into frame members
thereby enabling reliable x-y matrix grounding for the whole PV
array. Only one wire is required to ground the whole PV array and
the ground connection is uncompromised by the removal of a PV
module from the PV array.
[0099] Tolerance compensation--Parallel coupling minimizes
alignment problems due to variable tolerances within PV array via
an integral spring. Spring also resists unlocking of mechanism over
time and helps to minimize grounding problems by maintaining a
known amount of force on ground connection.
[0100] Multifunction frame--A frame is provided which supports PV
laminates and eliminates the need for a strut system which links
modules together in a PV array. Each frame member comprises a
specially shaped slot which enables the connection of parallel
couplings and mounting brackets to substantially the whole length
of all four sides of a PV module. Furthermore each slot comprises
flanges which enable high-strength interlocking and the connection
of snap-on options such as cosmetic flashings and debris
screens.
[0101] The above features provide many useful benefits including,
but not limited to: strutless design, minimal attachment points,
accessible yet hidden wiring, flexible mounting options, three
dimensional adjustability, rapid formation of PV array, better load
distribution, better airflow, more flexible wiring options, low
part count, improved aesthetics due to lower profile and better
alignment, and increased flexibility for orientation (landscape or
portrait o.k.).
[0102] When removing the strut from a PV mounting system,
significant structural challenges are revealed. We will now discuss
in more detail the structural advantages of the first embodiment
relative to prior art strutless systems.
[0103] First, coupling 50a maximizes structural integrity relative
to size by operating on frame 12 in a direction substantially
perpendicular to outside surface 16 (instead of parallel to it).
This fact enables the cost-effective creation of flanges 108AU,
108AL, 108BU, 108BL in frame 12 extrusion which provide a thick and
very strong surface that coupling 50a utilizes as a wall for
holding the ends of locking portions 104A, 104B. This arrangement
results in a very high pull-out strength as compared to the
press-fit resistance provided by prior art systems. The flanges
108AU, 108AL, 108BU, 108BL are described as cost-effective since
they run longitudinally in the same direction that an extrusion
process would run in order to extrude frame members 13 in a typical
manufacturing process. Creation of equivalent flanges running at 90
degrees to flanges 108AU, 108AL, 108BU, 108BL as required by prior
art systems requires additional machining operations.
[0104] Second, the major part of the coupling can be located in the
gap between modules instead of inside the frame member, thereby
reducing the required size for the frame.
[0105] Third, attaching coupling 50a to outside surface 16 of frame
12 with locking portions that engage positively inside both the top
and bottom frame member flanges 108AU and 108AL, allows coupling
50a to resist forces that would separate the opposing frame outside
surfaces 16, especially in comparison to prior art systems.
Furthermore, because it is these separating forces that are the
primary forces that we need to overcome with such a coupling, and
it intrinsically does this in an effective manner, it can be
designed smaller than prior art solutions, and will therefore
involve lower material costs.
[0106] Fourth, teeth 112AU, 112AL, 112BU, 112BL enhance the
longitudinal holding strength of coupling 50a since they are
circular to facilitate biting into frame 12 as rotating portion 100
is rotated to lock coupling 50a. These teeth therefore resist being
dragged along the longitudinal axis.
[0107] In addition to the structural advantages discussed above,
the grounding system provided by the first embodiment of the
present invention also has unique benefits. The system is more
reliable than the prior art since the amount of force supplied to
the grounding means is dependant on the stiffness of springs 106U,
106L. Once the correct spring size is determined, all couplings
will supply a consistent amount of force to the ground connection
and this force will not be dependant on how hard a technician
tightens the coupling.
[0108] It follows from the above discussion that the first
embodiment of the present invention provides significant advantages
over prior art systems. Other objects and advantages of the present
invention will also be discussed.
Second Embodiment
Structure
[0109] FIGS. 25-31 depict a second embodiment of the present
invention. This embodiment is similar to the first embodiment
described above except that it includes minor changes to the
framing and coupling systems in order to lower manufacturing costs
and simplify installation.
[0110] FIGS. 25-26 present a cross sectional view of two
interlocked modules 211A, 211B and a perspective view of four
interlocked PV modules 211A, 211B, 211C, 211D respectively. Slot
26A, 26B is removed from two opposing frame members 13 yielding a
hybrid, strut-like frame 212 with two un-slotted frame members 913
and two slotted frame members 213. Un-slotted frame members 913 may
be smaller and lighter weight than slotted frame members 213. In
another embodiment un-slotted frame members 913 are made from a
lightweight plastic material and are primarily used to protect
laminate 20 edges (instead of providing structural support). In
another embodiment frame members 913 are not used at all.
[0111] Frames 212A, 212B, 212C, 212D each comprise an outside
surface 216A, 216B, 216C, 216D; an inside surface 217A, 217B, 217C,
217D; a top surface 214A, 214B, 214C, 214D; and a bottom surface
215A, 215B, 215C, 215D (not all surfaces viewable in these
drawings). Four interlocked PV modules 211A, 211B, 211C, 211D are
oriented such that slots 226A, 226B with openings 227A, 227B
parallel each other and slots 226C, 226D with openings 227C, 227D
parallel each other. The two modules 211A, 211B comprise slot
inside surfaces 209AU, 209AL, 209BU, 209BL (modules 211B, 211C
comprising like surfaces which are not labeled). Thus, all slotted
frame members 213, except those around the perimeter of array 10,
may be located immediately adjacent to other slotted frame members
213, and all un-slotted frame members 913, except those around the
perimeter of array 10, may be located immediately adjacent other
un-slotted frames sides 913. The designation PV module 211 refers
to any PV module in array 10 and the designation 212 refers to any
PV module 211 frame in array 10. Likewise a slot 226 refers to any
slot 226A, 226B, 226C, 226D within array 10.
[0112] In order to maintain structural linking in both the x and y
directions, as is shown in the first embodiment described above,
the second embodiment of the present invention replaces coupling
50a with a parallel coupling 50b in some locations. In other
locations a parallel coupling 50j is utilized in place of coupling
50a. In locations where two frame members 13 have been changed to
un-slotted frame members 913 there are no couplings since there is
no slot 26 for coupling connection. Parallel coupling 50b is also
referred to as a double coupling or series-parallel coupling 50b
because it further comprises a series coupling portion 162 which is
utilized to provide a series coupling connection to a second pair
of adjacent PV modules. Thus parallel coupling 50b interlocks four
PV modules 211A, 211B, 211C, 211D instead of two as is typical in
prior art systems. A more detailed description of the layout of
couplings 50b and 50j is provided below. All couplings 50j and 50b
are shown here in horizontal seams 150, but other embodiments
provide all couplings 50j and 50b in vertical seams 152. In still
other embodiments frame members 13 are substantially similar on all
four sides and therefore couplings 50j and 50b are located in both
the horizontal 150 and vertical seams 152.
[0113] FIG. 27 depicts a perspective view of a generally
rectangular-shaped parallel coupling 50b. Coupling 50b comprises
two parallel coupling portions 50bb and a series coupling portion
162. Parallel coupling portions 50bb are similar to couplings 50j
(described below) except that cthey may be shaped slightly
differently in order to work well with series coupling portion 162.
For example, in one embodiment parallel coupling portions 50bb are
similar to couplings 50j except that they further comprise retainer
portions which enable them to be movably secured to series coupling
portion 162, thereby allowing coupling 50b to be deployed as a
one-piece unit in the field. In the present embodiment under
discussion coupling portions 50bb are the same as couplings 50j
thus allowing coupling 50b to be a three piece unit comprising two
parallel coupling portions 50bb and one series coupling portion
162. In another embodiment more than two coupling portions 50bb are
utilized for additional strength. In still another embodiment
series coupling portion 162 comprises retainer portions which
enable parallel coupling portions 50bb to be movably secured to
series coupling portion 162, thereby resulting in a one-piece
coupling 50b.
[0114] Referring to FIGS. 25-27, series coupling portion 162
comprises a first side 164 adapted to mate with outside surfaces
216A, 216C of the four interlocked PV modules 211A, 211B, 211C,
211D. First side 164 comprises three male protrusions which mate
with frames 212A, 212C to increase the strength of frames 212A,
212C at the point of coupling. Male protrusion 165 is adapted for
insertion into auxiliary slots 224A, 224C in frames 212A, 212C and
may be tapered slightly to insure a snug fit is maintained despite
tolerance issues. Male protrusion 166 is adapted for insertion into
slots 226A, 226C in frames 212A, 212C and comprises teeth 168U,
168L which bite into frames 212A, 212C to insure solid electrical
ground contact and to enhance the structural connection between PV
modules 211A, 211C. Male protrusion 166 may be tapered. Male
protrusion 167 is adapted to slide just beneath frames 212A, 212C
and may be tapered as well. In other embodiments male protrusions
165, 166, 167 may not be tapered. Series coupling portion 162
further comprises at least two slots or holes 170A, 170B which
allow insertion of parallel coupling portions 50bb as discussed
below and a second side 172 which faces away from PV modules 211A,
211C when series coupling portion 162 is installed. In another
embodiment teeth 168U, 168L are replaced by teeth on a different
surface of series coupling portion 162 or a different portion of
coupling 50b. In other embodiments series coupling portion 162 has
various numbers of male protrusions. In still another embodiment
there are no male protrusions on series coupling portion 162. We
contemplate making series coupling portion 162 in a length of
approximately 3-12'' and out of a rigid material such as aluminum
or steel, though other materials and lengths are possible.
[0115] FIG. 28 shows a perspective view of parallel coupling 50j
which comprises all of the same portions as coupling 50a except the
following. First, shaft portion 102A, designated here as 232A, has
been extended by approximately the width of bracket 132. Second,
rotating portion 100 has been replaced by rotating portion 200
comprising four springs 236A, 236B, 236C, 236D, (not all viewable
here), two for each side of coupling 50j oriented approximately 180
degrees apart. And third, spring bores 110U, 110L have been
replaced by spring bores 240A, 240B, 240C, 240D to correspond with
new springs 236A, 236B, 236C, 236D. Coupling 50j further comprises
locking portions 204A, 204B which function the same as locking
portions 104A, 104B. All remaining portions of coupling 50j are the
same as coupling 50a and are thus not specifically designated here.
Parallel coupling portion 50bb in this second embodiment is the
same as coupling 50j and thus also references the same
designations.
[0116] FIG. 29 shows a perspective view of height adjustable
bracket 132 and parallel coupling 50j. Another advantage of the
second embodiment of the present invention is that extended shaft
portion 232A allows coupling 50j to perform a dual function of
interlocking adjacent PV modules together as discussed above while
also attaching bracket 132 to PV module 11. This feature
substantially reduces installation time when compared to prior art
systems that require the tightening of separate fasteners for
couplings and brackets. One skilled in the art will also recognize
that vertical adjustment slot 140 in bracket 132 is approximately
perpendicular to slot 26A, 26B, and that springs 236A, 236B, 236C,
236D are oriented so that in first position 91 all four springs are
free and uncompressed in the same way as coupling 50a. Many other
spring variations are possible within the scope of the present
invention.
[0117] FIG. 30 provides a cross-section showing two adjacent PV
modules 212A, 212B which are interconnected with coupling 50j.
Coupling 50j is shown in first position 91 as discussed above. When
rotated approximately 90 degrees, coupling 50j interlocks frames
212A and 212B together and simultaneously compresses bracket 132
against frame 212A. Thus, channel nut 134 and channel bolt 136 are
no longer needed.
Second Embodiment
Operation
[0118] FIG. 31 is the same as FIG. 11 except that PV array 10
utilizes the framing and coupling system of the second embodiment.
Brackets 132 are shown in the same locations except now they are
connected to frames 212A, 212B, 212C, 212D via couplings 50j,
thereby reducing total part count and installation time required
for PV array 10. Series-parallel couplings 50b bridge the corner
points where the four corners of PV modules 211A, 211B, 211C, 211D
meet. For example, a coupling 50b is shown bridging a corner point
295 where four PV modules 211A, 211B, 211C, 211D meet. Parallel
coupling portions 50bb interlock modules 211A, 211B and 211C, 211D
while series coupling portion 162 interlocks modules 211B, 211D and
211A, 211C. Please note that a second series coupling portion
between 211A, 211C is possible but not required since parallel
coupling portions 50bb lock frame 212A to frame 212B and frame 212C
to frame 212D along with series coupling portion 162.
[0119] Thus, the two axis parallel interlock support system 160
from the first embodiment is replaced by a single axis parallel
interlock support system 260 which may run along the x-axis or
y-axis. As shown in FIG. 31, parallel coupling portions 50bb and
parallel couplings 50j lock adjacent frame members 213 side to side
in parallel which creates vertical rows of paired frame members 213
along the y-axis. Series coupling portions 162 interlock frame
members 213 longitudinally along the x-axis, thereby connecting the
vertical rows and increasing the overall strength of the system.
Series coupling portion 162 is located between rotating portion 100
and outside surface of frames 216. And since parallel coupling
portion 50bb is rotatable relative to series coupling portion 162,
a rotation of rotating portion 100 firmly compresses series
coupling portion 162 into frames 212A, 212C. This action serves to
substantially increase the strength of frames 212A, 212C relative
to a z-axis load (such as wind) in the region of coupling 50b since
z-axis loads are distributed longitudinally down frames 212A, 212C.
While some prior art couplings do also provide increased z-axis
strength due this same effect, series coupling portion 162 may be
substantially stronger for the following reasons: (a) since series
coupling portion 162 is not fully contained within a slot or
internal cavity of frames 212A, 212C, it is able to be much taller
in the z-direction thereby increasing strength; (b) coupling
portion 162 is secured to frames 212A, 212C by a compressive force
about a portion of frames 212A, 212C which increases strength
instead of a tensile force which tends to deform the frame and
decrease strength; (c) coupling portion 162 comprises upper 165 and
lower 167 male protrusions which tend to prevent deformation of
frames 212A, 212C under load since they prevent widening of opening
227A as seen in FIG. 25; and (d) coupling portion 162 has no fixed
center point and therefore may be slid in slots 226A, 226C to match
up with high load areas.
[0120] Accordingly, a rotation of parallel coupling portion 50bb
from first position 91 to third position 93 causes locking portion
204A to bear against inside surfaces 209AU, 209AL of slot 226A and
rotating portion 200 via springs 236A, 236C to bear against series
coupling portion 162 which in turn bears against an opposing frame
surface, outside surface 216A. In this case the bearing action of
rotating portion 200 is transferred through springs 236A, 236C and
series coupling portion 162 to frame 212A. Therefore springs 236A,
236C and series coupling portion 162 are also referred to as force
transfer portions. Since there is no series coupling portion 162
between rotating portion 200 and frame 212B, this portion of the
coupling process proceeds the same as discussed above for module
12B. That is, locking portion 204B bears against inside surfaces
209BU, 209BL of slot 226B and rotating portion 100 via springs
236B, 236D bears against an opposing frame surface, outside surface
216B. Thus, PV frames 212A and 212B are locked to coupling 50b via
rotation of rotating portion 200 from first position 91 to third
position 93. The other half of coupling 50b operates in the same
way to lock frames 212C and 212D to coupling 50b. Thus it is clear
that coupling 50b securely interlocks PV modules 211A, 211B, 211C,
and 211D together by bearing against opposing surfaces on each
frame 212A, 212B, 212C, 212D upon rotation of rotating portions
200. In other embodiments devices which are removable from a
mounted PV module 211 along with coupling 50b, such as washers,
pressure distribution plates, and springs, are placed between
coupling 50b and frame 212. In these cases such devices are
sometimes referred to as force transfer portions and are considered
to be part of coupling 50b in the same way that series coupling
portion is so incorporated. On the other hand, brackets and struts
which span between PV modules 211 and/or are attached to a mounting
surface are not considered to be a part of coupling 50b since they
are not removable with coupling 50b.
[0121] As shown in FIG. 30, the second embodiment of the present
invention provides a means for reducing parts and labor costs by
combining the function of attaching bracket 132 with the function
of interlocking two adjacent PV modules 211A, 211B. Thus, the
installation of PV array now has one less step. To our knowledge
there are no prior art systems which teach a combined functionality
coupling which can both couple the sides of two adjacent PV modules
together in parallel and simultaneously secure a height adjustable
bracket to the side of frame 212A.
[0122] The basic steps involved in the forming and mounting of PV
array 10 according to the second embodiment of the present
invention may be as follows:
[0123] Step 1: Secure a first PV module 211 to a mounting surface
144 with at least one bracket 132.
[0124] Step 2: Interlock a second PV module 211 to the first PV
module 211 with at least one parallel coupling 50b or 50j which
interlocks the sides of two adjacent frame members together in
parallel.
[0125] Step 3: Attach second PV module 211 to mounting surface 144
with at least one bracket 132.
[0126] Step 4: Repeat steps 2 and 3 for all remaining PV modules
211 in PV array 10, successively interlocking each new PV module
211 to the side of a mounted PV module 211 and attaching at least
one bracket 132 to each module.
[0127] Parallel couplings 50b may be used at substantially all
corner points 295 where four PV modules 211 meet. Substantially all
brackets which are mounted in the seams between PV modules 211 may
be attached via couplings 50j. Final tightening of each coupling
50b, 50j and bracket 132 connection is flexible and does not
necessarily coincide with initial placement in array 10 of that
module 211. This flexibility allows PV modules 211 to be
temporarily positioned in the array while others are positioned or
while wiring or other installation issues are handled. Since all
couplings 50b and 50j are capable of being tightened from the top,
PV modules 211 can be moved into locked mode at any time. One
skilled in the art will recognize that the 2-axis nature of the
couplings in the embodiment under discussion means that PV modules
211 can be installed in any order and in substantially any shape
for PV array 10 as long as each new PV module 211 is interlocked to
a mounted PV module 211, and all new modules 211 are added to a
mounted module which has a portion of a frame member 213 free (not
already interlocked to another PV module). Stepped arrays as
discussed above are not possible when using couplings 50b.
[0128] In another embodiment which is similar to the first
embodiment discussed above, couplings 50j replace couplings 50a
thereby enabling the capture of brackets 132 with couplings 50j,
while also retaining the benefits of an all-parallel coupling
installation as discussed.
Third Embodiment
[0129] FIGS. 32-34 depict a third embodiment of the present
invention. This embodiment is similar to the first embodiment
described above except that the orientation of the coupling action
of coupling 50a has been altered and a retaining element has been
added. Instead of bearing against vertically oriented opposing
surfaces on frame 12, a parallel coupling 50c is provided to bear
against horizontally oriented opposing surfaces on frame 12.
[0130] FIG. 32 shows a perspective view of parallel coupling 50c
which has been installed into slots 26A, 26B of two adjacent PV
modules 11A, 11B but not fully tightened down. Frames 12A, 12B have
been cut away so that coupling 50c shows in this view. FIG. 33
provides an exploded view of the two sides of a retainer portion
354L, 354R. FIG. 34 provides a cross-section view cut through two
adjacent PV modules 11A, 11B which are coupled together with
parallel coupling 50c. The cross section is cut partially through
coupling 50c as indicated.
[0131] Referring to FIGS. 32-34, coupling 50c comprises retainer
portion 354 which holds a locking portion 304 and a nut portion 306
via position tabs 362. Locking portion 304 may comprise a first
side 304A for locking with frame 12A and a second side 304B for
locking with frame 12B. Nut portion 306 may comprise a first side
306A for securing to frame 12A and a second side 306B for securing
to frame 12B. Retainer portion 354 may comprise two substantially
identical halves 356L, 356R which mate together via male and female
arm pairs 358LM, 358RF and 358LF, 358RM. Two halves 356L, 356R
capture locking portion 304 and nut portion 306 and hold them in
position as coupling 50c is inserted into slots 26A, 26B. During
insertion, snap-lock portions 360LA, 360LB, 360RA, 360RB flex
downward then snap back up into position once inserted past flanges
108AU, 108BU. We contemplate making retainer portion 354 out of a
plastic material, though many other semi-flexible materials are
also suitable. A bolt or threaded rotating portion 300 comprises a
head 352 which accepts a tool from above and is used to tighten and
loosen coupling 50c about frames 12A, 12B. Locking portion 304
comprises a hole for rotating portion 300 which is larger than the
outside diameter of rotating portion 300 and is not threaded. Nut
portion 306 is drilled and tapped for the threads on rotating
portion 300 and comprises teeth 364 for biting into frames 12A, 12B
when coupling 50c is tightened, thereby providing electrical ground
continuity between modules 11A, 11B and enhancing the structural
connection of coupling 50c. We contemplate making locking portion
304, and nut portion 306 out of a rigid material such as aluminum
or steel, though other materials are also suitable.
[0132] Operation of the apparatus of the third embodiment is
similar to the first embodiment except for the operation of
coupling 50c. Coupling 50c may be pre-assembled in a factory by
mating halves 356L, 356R about locking portion 304 and nut portion
306 so that coupling 50c may be deployed as a one-piece unit ready
for installation in the field. To install, coupling 50c is inserted
at substantially any point along slot 26A in PV module 11A.
Coupling 50c is inserted with snap-lock portions 360LA, 360RA
pointing towards opening 27A in slot 26A and with a direction of
travel which is substantially parallel with the plane of laminate
20A and substantially perpendicular to the length of slot 26A.
Coupling 50c is inserted until snap-lock portions 360LA, 360RA
clear flange 108AU and snap into place. Coupling 50c is now in
positioning mode and ready to be coupled to PV module 11B. With
coupling 50c being held in place by retainer portion 354, PV
modules 11A and 11B are free to be moved independently from each
other. Thus, this embodiment provides the same independent movement
capability in positioning mode as discussed above for the first
embodiment, but coupling 50c is held in position during this phase
by retainer portion 354 instead of locking portions 104A, 104B. To
complete the coupling operation, coupling 50c is inserted into slot
26B until it snaps in place as described above. Then a driver is
used to engage rotating portion head 352 and rotate rotating
portion 300 which pulls nut portion 306 toward slots 26A, 26B and
pushes locking portion 304 away from slots 26A, 26B.
[0133] More specifically, rotation of rotating portion 300 causes
locking portion 304 and nut portion 306 to move closer together
which in turn causes locking portion 304 to bear against inside
surfaces 309AL, 309BL of slots 26A, 26B and nut portion 306 to bear
against opposing surfaces, bottom surfaces 15A, 15B of frames 12A,
12B. Thus it is clear that coupling 50c securely interlocks PV
modules 11A and 11B together by bearing against opposing surfaces
on each frame 12A, 12B upon rotation of rotating portion 300. As
locking portion 304 and nut portion 300 tighten about frames 12A,
12B position tabs 362 bend or break since they are overpowered by
the force delivered by the driver to rotating portion 300. Once
rotating portion 300 is tight, coupling 50c is now in locked mode.
Sliding mode can be accessed at any time by loosening rotating
portion 300, which is still accessible from the top even after
array 10 has been formed. As with the first embodiment, sliding
mode allows sliding of coupling 50c over to a neighboring seam 150
or 152 so that a module can be removed from the middle of a formed
PV array 10.
[0134] In other embodiments a surface area of contact between
locking portion 304 and frames 12A, 12B is increased by widening or
removing altogether flanges 108AL, 108BL. Another embodiment
extends locking portion 304 and nut portion 306 with series
coupling portions so that they reach over to the next pair of
modules, thereby creating a four module coupling similar the second
embodiment above. In another embodiment locking portion 304
comprises a spring element for bearing against an inside surface of
slot 226. In yet another embodiment retainer portion 354 is shaped
differently so that it comprises spring elements for the top and
bottom flanges.
Fourth Embodiment
[0135] FIGS. 35-38 depict a fourth embodiment of the present
invention. This embodiment is similar to the second embodiment as
described above except that locking portions 204A, 204B and
rotating portions 200 have been altered slightly.
[0136] FIG. 35 depicts a perspective view of a parallel coupling
50d installed in two adjacent PV modules 211A, 211B and FIG. 36
presents a perspective view of coupling 50d with a rotating portion
400CD which has been slid over to the right (see below for
explanation). FIG. 37 provides a cross section cut through a seam
between four PV modules 211A, 211B, 211C, 211D which have been
interlocked together with coupling 50d, and FIG. 38 depicts a
perspective view of four interlocked PV modules 211A, 211B, 211C,
211D. As is consistent with the present invention, parallel
coupling 50d comprises locking portions 404AC, 404BD and rotating
portions 400AB, 400CD which serve to compress frames 212 upon
movement of coupling 50d into locked mode. Locking portions 404AC,
404BD differ from locking portions 104A, 104B in that they have
been elongated with series coupling portions 462 to bridge between
the two pairs of PV modules 211A, 211C and 211B, 211D; thus
enabling coupling 50d to interlock four adjacent PV modules in a
similar manner to the second embodiment except without requiring a
separate series coupling portion 162. Coupling 50d is deployable in
the field as a one-piece unit which is capable of interlocking four
PV modules 211A, 211B, 211C, 211D together. Instead of utilizing
two parallel coupling portions 50bb plus series coupling portion
162 as discussed for the second embodiment, this embodiment
essentially allows two coupling members to share two locking
portions 404AC, 404BD thereby creating a "double coupling"
device.
[0137] Since locking portions 404AC, 404BD can no longer rotate
within slots 26A, 26B, 26C, 26D to tighten coupling 50d, threaded
shaft portions 402A, 402B, 402C, 402D (not all visible) replace
shaft portions 232A, 232B and thread into threaded holes 490A,
490B, 490C, 490D (not all visible) in locking portions 404AC,
404BD. Opposite ends of shaft portions 402A, 402B and 402C, 402D
are provided with opposite handed threads so that rotation of shaft
portions 402A, 402B, 402C, 402D causes locking portions 404AC,
404BD to move horizontally in opposite directions from each other
according to the arrow shown in FIG. 36. Rotating portions 400AB,
400CD replace rotating portions 100 and function the same except
that rotating portions 400AB, 400CD are decoupled from shaft
portions 402A, 402B, 402C, 402D allowing them to move horizontally
independently from shaft portions 402A, 402B, 402C, 402D according
to the arrow shown on FIG. 36. Rotating portions 400AB, 400CD,
however, cannot rotate independently from their respective shaft
portions 402A, 402B and 402C, 402D as they are provided with
hexagonal bores 492AB, 492CD to match hexagonal portions 494AB,
494CD which may be rigidly connected or formed from shaft portions
402A, 402B and 402C, 402D respectively. In other embodiments
hexagonal parts are provided with other shapes to achieve the same
functionality.
[0138] Referring specifically to FIG. 37, it is evident that a
rotation of rotating portion 400AB with a wrench in a first
direction causes locking portions 404AC, 404BD to pull frames 212A,
212B towards each other. Since rotating portion 400AB is slidable,
it slides along hexagonal shaft portion 494AB until it is
contacting both outside surfaces 216A, 216B of PV modules 211A,
211B. Additional rotation in the first direction after both frames
212A, 212B have contacted rotating portion 400AB causes locking
portion 404AC to bear against inside surfaces 209AU, 209AL of slot
226A and rotating portion 400AB to bear against an opposing frame
surface, outside surface 216A. Likewise, rotation of rotating
portion 400AB causes locking portion 404BD to bear against inside
surfaces 209BU, 209BL of slot 226B and rotating portion 400AB to
bear against an opposing frame surface, outside surface 216B. Thus,
PV frames 212A and 212B are locked to coupling 50d via rotation of
rotating portion 400AB. The other half of coupling 50d operates in
the same way to lock frames 212C and 212D to coupling 50d. Thus it
is clear that coupling 50d securely interlocks PV modules 211A,
211B, 211C, and 211D together by bearing against opposing surfaces
on each frame 212A, 212B, 212C, 212D upon rotation of rotating
portions 400AB, 400CD.
[0139] Once both rotating portions 400AB and 400CD have been
rotated into their fully tightened positions, coupling 50d is in
locked mode as discussed earlier. Rotation of rotating portion
400AB in a second direction which is opposite the first direction
decouples PV modules 211A and 211B. If both rotating portions 400AB
and 400CD are rotated so as to decouple PV modules 211A, 211B and
211C, 211D respectively, then coupling 50d is shifted into sliding
mode and is therefore free to slide completely over into the slots
of either PV modules 211A, 211B or 211C, 211D.
[0140] FIGS. 35 and 37 also reveal raised portions or teeth 496AC
and 496BD on locking portions 404AC, 404BD which bite into frames
212A, 212B, 212C, 212D when coupling 50d is tightened thereby
providing a reliable electrical ground connection between all four
PV modules 211A, 211B, 211C, 211D and enhancing the structural
properties of coupling 50d. These drawings also show optional
retainer portions 454AC, 454BD on the top and bottom of locking
portions 404AC, 404BD. Retainer portions 454AC, 454BD may comprise
a flexible material which allows insertion of coupling 50d into a
pair of slots 226A, 226B from the end but prevents coupling 50d
from falling back out on its own or from sliding around prior to
being shifted into locked mode. Another embodiment is the same as
the fourth embodiment except only comprises one rotating portion
and is approximately half as long. This embodiment functions the
same but is optimized to interlock two PV modules 211 together
instead of four.
[0141] The fourth embodiment provides several advantages relative
to some of the other embodiments discussed herein. The sliding
capability of rotating portion eliminates the need for springs
236A, 236B, 236C, 236D; incorporation of a series coupling portion
462 into locking portions 404AC, 404BD eliminates the need for
series coupling portion 162; and manufacturing costs may be
reduced. However, series coupling portion 462 is not as strong as
series coupling portion 162 since it must be contained within slots
226A, 226B.
Additional Embodiments
[0142] FIGS. 39-40 depict a perspective view and a cross section
cut between two interlocked PV modules 211A, 211B respectively for
an alternate embodiment which is similar to the fourth embodiment
as shown in FIGS. 35-38. This embodiment, which helps to lower
manufacturing costs, provides a parallel coupling 50e in which
rotating portions 400AB, 400CD have been eliminated in favor of a
plurality of rotating portions 500. This arrangement enables the
attachment of coupling 50e to frames 212 via a bearing action
against two opposing surfaces which are both inside of slot 226
instead of one internal and one external as shown for the fourth
embodiment. Locking portions 504AC, 504BD are almost the same as
before, but now retainer portions 454AC, 454BD and teeth 496AC,
496BD have been eliminated. Locking portions 504AC, 504BD are
rigidly joined together by y-axis spacer block 574 with x-axis
spacer screw 576. Spacer screw 576 is in place as shown during
initial installation so that each module can be slid up to screw
576. But if a module needs to be removed from array 10 after
compete installation, spacer screw 576 is removed and coupling 50e
is slid completely over to the next horizontal seam 150. Locking
portions 504AC, 504BD also comprise series coupling portions 562 as
before. Rotating portions 500 comprise shaft portions 502 which may
be threaded and further provided with a cupped end for biting into
frames 212 to insure reliable electrical ground and to enhance the
structural properties of coupling 50e. Thus, rotating portions 500
comprise a portion which resides inside of slots 226 and a portion
which resides outside of frames 212. The external portion of
rotating portions 500 may also comprise a hexagonal or other shaped
head portion 503 which allows rotation from above similar to
rotating portions 400AB, 400CD.
[0143] Referring to FIG. 40 and the coupling process between PV
modules 211A, 211B, a rotation of rotating portions 500 causes them
to bear against inside surfaces 507A, 507B of slots 226A, 226B
thereby forcing locking portions 504AC, 504BD to bear against
opposing inside surfaces 509AU, 509AL, 509BU, 509BL, thereby
securely coupling the sides of adjacent PV modules 211A and 211B
together. Since coupling 50e, like coupling 50d, is designed to
connect four adjacent PV modules together, one skilled in the art
will recognize that the coupling of modules 212C and 212D utilizes
the same process as just discussed for PV modules 212A and 212B.
Thus it is clear that coupling 50e securely interlocks PV modules
211A, 211B, 211C, and 211D together by bearing against opposing
surfaces on each frame 212A, 212B, 212C, 212D upon rotation of
rotating portions 500.
[0144] In another embodiment similar to the previous the half of
locking portions 504AC, 504BD that interlock PV modules 211C, 211D
together is eliminated along with series coupling portion 562. This
leaves a two-module parallel coupling which is possibly suitable
for use in PV array 10 along with couplings 50e (like at the ends
of rows). In another embodiment a coupling is formed out of a
single locking portion 504AC along with associated rotating
portions 500 from coupling 50e. While this embodiment is similar to
prior art series couplings, it differs significantly in that the
coupling action results from a bearing on two opposing surfaces of
slot 226 (for increased strength). Furthermore, there is no
press-fit action and the grounding is provided by rotating portions
500. Another embodiment is similar to the embodiment of FIGS. 39-40
except that spacer block 574 is slidably held between locking
portions 504AC, 504BD via pins between locking portions and is
taller than slot opening 227A. This variation works similarly to
the fourth embodiment except that instead of rotating portions
sliding to set the spacing between modules, it is the spacer block
which slides. In still another embodiment multiple spacer blocks
are utilized.
[0145] FIGS. 41-42 depict a cross section cut between two
interlocked PV modules 11A, 11B and a perspective view respectively
for an alternate embodiment which is similar to the first
embodiment as shown in FIGS. 1-24, but may lower manufacturing
costs. This embodiment provides a coupling 50f with locking
portions 604A, 604B which are threaded into rotating portion 600
via shaft portions 602A, 602B instead of being rigidly connected
thereto. Rotating portion 600 has also been trimmed down in size so
that coupling 50f can not only be slid into the slots 26A, 26B of a
neighboring pair of PV modules (in sliding mode), but so that it
can also "turn the corner" and move from an x-axis direction slot
into a y-axis direction slot and vice versa. This feature enables
removal of a PV module even when the slots within the PV array are
not aligned in one direction. This may occur in some cases by
accident, or in other cases due to tolerance issues, or for
architectural reasons. Springs 606U, 606L on rotating portion 600
are smaller than before but function the same. Shaft portions 602A,
602B are provided with opposite threading so that rotation of
rotating portion 600 causes locking portion 604A to bear against
inside surface 109AU, 109AL of slot 26A and rotating portion 600 to
bear against an opposing surface, outside surface 16A of frame 12A.
Likewise, locking portion 604B bears against inside surface 109BU,
109BL of slot 26B and rotating portion 600 bears against an
opposing surface, outside surface 16B of frame 12B. Thus it is
clear that coupling 50f securely interlocks PV modules 11A, 11B
together by bearing against opposing surfaces on each frame 12A,
12B upon rotation of rotating portion 600.
[0146] In another embodiment similar to the previous one discussed,
locking portion 604A and shaft portion 602A is replaced by locking
portion 104A and shaft 102A from the first embodiment.
[0147] FIGS. 43-44 depict a perspective view and a cross section
cut between two interlocked PV modules 11A, 11B respectively for an
alternate embodiment which is similar to the third embodiment as
shown in FIGS. 32-34. This embodiment lowers the amount of
installation time required by replacing rotating portion 300 with a
shaft 750 and cams 780A, 780B on a parallel coupling 50g. Cams
780A, 780B are rigidly connected to rotating portion 700 which is
rotatable about axle 788 with a wrench from above. Shaft 750
comprises a flat, narrow portion 774 with a hole (not visible) that
shaft 788 runs through, a medium diameter portion 775, a larger
diameter portion 776, and a head portion 752. A washer portion 706
with sides 706A, 706B is positioned on shaft portion 776 and
comprises a bore (not viewable) larger than shaft portion 776 but
smaller than a diameter of head portion 752. A locking portion 704
with sides 704A, 704B is positioned on shaft portion 775 and
comprises a bore (not viewable) larger than shaft portion 775 but
smaller than shaft portion 776. Locking portion 704 comprises
thicker portions 785A, 785B and is pushed down onto ledge 788 by
retainer springs 756A, 756B (in direction of arrow) when not
installed.
[0148] To operate, cams 780A, 780B are rotated so that they are not
touching locking portion 704. Then coupling 50g is snapped onto
frame 12A. We contemplate making springs 756A, 756B out of a
flexible material such as rubber or similar so that they allow
locking portion 704 and washer portion 706 to open up when pushed
onto frame 12A. Thicker portions 785A, 785B in conjunction with
springs 756A, 756B prevent coupling from falling off, thus enabling
positioning mode. Frame 12B and coupling 50g are wedded in the same
fashion. Once coupling 50g is loosely positioned onto both frames
12A, 12B, then a wrench is used to rotate rotating portion 700
which in turn rotates cams 780A, 780B, which force locking portion
704 and washer portion 706 to move toward each other. This movement
causes locking portion 704 to bear against inside surfaces 309AL,
309BL of slots 26A, 26B and washer portion 706 to bear against
opposing surfaces, bottom surfaces 15A, 15B of frames 12A, 12B.
Thus it is clear that coupling 50g securely interlocks PV modules
11A, 11B together by bearing against opposing surfaces on each
frame 12A, 12B upon rotation of rotating portion 700. Raised teeth
764 bite into frames 12A, 12B upon tightening, thereby ensuring
ground contact and enhancing structural properties as described
earlier. In another embodiment springs 756A, 756B comprise a
resting position as depicted and therefore do not push locking
portion down onto ledge 788 when not installed. Another embodiment
provides a cam shape which sets the straight-up position as free,
then rotating one direction moves to positioning mode and rotating
the other way enables locked mode. And another embodiment provides
a handle connected to rotating portion 700.
[0149] FIGS. 45-46 depict a perspective view and a cross section
cut between two interlocked PV modules 11A, 11B respectively for an
alternate embodiment which is similar to the third embodiment as
shown in FIGS. 32-34. This embodiment may provide a lower
manufacturing cost by replacing retainer portion 354 with retainer
springs 856A, 856B between a locking portion 804 and a nut portion
806. Similar to the previous embodiment, a coupling 50h comprises
retainer springs 856A, 856B which pull a locking portion 804 with
sides 804A, 804B down onto a ledge 888 when not installed (in
direction of arrow). Coupling 50h is snapped onto frame 12A and
temporarily held in place during positioning mode by springs 856A,
856B and thicker portions 885A, 885B of locking portion 804.
Thicker portions 885A, 885B may also be sized to provide a positive
engagement for lateral loads. Rotation of rotating portion 300
causes the coupling to shift to locked mode as described for the
third embodiment. Another variation of this embodiment provides
springs 856A, 856B which are in their resting state as shown so
that ledge 888 is not needed. Yet another variation replaces
thicker portions 885A, 885B with teeth that interlock with frame
and another provides grounding spikes on locking portion 804.
[0150] FIGS. 47-48 depict a cross section cut between two
interlocked PV modules 11A, 11B and a perspective view respectively
for an alternate embodiment which is similar to the first
embodiment as shown in FIGS. 1-24. The primary distinction of the
present embodiment, which describes a coupling 50i, is that locking
portions 104A, 104B have been replaced by pairs of locking portions
904AU, 904AL and 904BU, 904BL respectively. The paired locking
portions 904AU, 904AL and 904BU, 904BL are provided with ridged
camming surfaces 982AU, 982AL, 982BU, 982BL which are adapted to
bear against inside surfaces 909AU, 909AL, 909BU, 909BL when a
rotating portion 900 is rotated. Rotating portion 900 is rigidly
connected to locking portions 904AU, 904AL, 904BU, 904BL via a pair
of shafts (not visible) which run through retainer portions 954A,
954B. Retainer portions 954A, 954B may be made of a flexible
material so that insertion of retainer portions 954A, 954B into
slots 26A, 26B deforms or bends retainer portion enabling
positioning mode. Ridges on ridged camming surfaces 982AU, 982AL,
982BU, 982BL bite into frames 12A, 12B upon rotation thereby
securing ground contact and increasing the strength of coupling
50i. Locking portions 904AU, 904AL, 904BU, 904BL comprise flattened
portions 980A, 980B which enable insertion when properly aligned
with slots 26A, 26B since they reduce the overall width to less
than opening 27A, 27B. Thus, insertion of locking portions 904AU,
904AL, 904BU, 904BL into slots 26A, 26B followed by a rotation of
nut portion 900 causes locking portions 904AU, 904AL, 904BU, 904BL
to bear against opposing surfaces 909AU, 909AL, 909BU, 909BL,
thereby securely coupling the sides of adjacent PV modules 11A and
11B together. In another embodiment locking portions 904AU, 904AL,
904BU, 904BL are rotated 90 degrees from the orientation shown so
that rotation of rotating portion 900 causes a camming action
between the back of slot 26 and inside surfaces 109AL, 109AU. In
another embodiment retainer portions 954A, 954B are eliminated in
favor of an offset cam arrangement similar to the first embodiment
where one cam is insertable in both first position 91 and second
position 92.
[0151] FIGS. 49-50 depict an embodiment which is similar to the
second embodiment discussed above except that a spacer block 274
has been added. FIG. 49 is the same as 26 except spacer block 274
is shown installed onto series coupling portion 162 via a slot 276
on the bottom side. FIG. 50 provides a perspective view of spacer
block 274 which further reveals slot 276 and a bottom mounted wire
clip 285 for securing PV module 11 output wires 22neg, 22pos.
Securing wiring in this way is a substantial improvement over prior
systems since wire clip 285 provides a means of preventing wires
from unsightly and unsafe drooping onto roof surfaces. Furthermore,
the horizontal seam 150 between PV modules 211A, 211B and 211C,
211D is set for this embodiment slightly wider than the width of
wiring plugs 24neg, 24pos; therefore troubleshooting and
maintenance of PV array 10 wiring systems is greatly simplified
since one can easily snap spacer block 274 up and off from the top
and pull wires 22neg, 22pos right up through seam 150 for
inspection and repair. No decoupling of PV modules 11A, 11B is
required in order to maintain the wiring system between them. In
another embodiment a wire clip comprises a spring clip which snaps
into slot 26A thereby allowing the strapping of wires substantially
along the whole length of frame 26A. In still another embodiment a
hinged wire clip 285 snaps into slot 26A and swings underneath
module 11 to hide it, then back up into the gap between modules 11
to allow access.
[0152] FIGS. 51-52 depict an embodiment of the present invention
which is similar to the second embodiment discussed above except
that PV array 10 is installed on an open canopy structure 144C
instead of roof 144R. Installation on a different mounting surface
144 for PV array 10 requires minor changes to brackets 132 and
series coupling portions 162 as will be discussed below.
[0153] FIGS. 51 and 52 depict a perspective view and a side view
respectively of PV array 10 installed on canopy structure 144C.
Canopy 144C comprises purlins 180 which are supported by girders
182 which in turn are supported by vertical columns 184. We
contemplate vertical columns 184 of approximately the same height
for this embodiment in order to demonstrate that substantially any
tilt angle (from flat to vertical) for PV array 10 is suitable. For
example, many prior art systems require a specific slope to a PV
array in order for the interlocking or mounting systems to function
properly, but the coupling and framing systems described herein do
not place any such limitations on PV array 10. PV array 10, as
shown in FIG. 51, comprises a total of sixteen PV modules which are
mechanically interlocked in groups of four with couplings 50b in
the same manner described in FIGS. 25-28. Use of a different
mounting surface 144 in this embodiment requires slight changes to
the brackets and the layout of series coupling portions 162. The
detail in FIG. 51 shows a double bracket 186 which is utilized to
directly connect two frames 212 to purlins 180 in the central
vertical seam 152 where the groups of four PV modules 211A, 211B,
211C, 211D come together. Double bracket 186 comprises vertical
portions 187L, 187R with vertical adjustment slots 188 for
connecting to frames 212 in the same way as bracket 132 only this
bracket connects to two adjacent PV modules 211. Each horizontal
row along the central vertical seam 152 comprises one double
bracket 186, but not all are visible here. Double bracket 186
further comprises U-bolt slots 190L, 190R (not all visible), U-bolt
192, nut and washer 193 for securing double bracket 186 to purlin
180, and a series coupling portion 962. PV modules 211 are secured
to the other two purlins by means of a bracket 132U which is
similar to double bracket 186 except that there is only one
vertical portion 187 since this is the last row of PV modules
211.
[0154] Regarding the present embodiment under discussion, it is
also important to note that there are no strut or PV frame support
members required as would be the case for most prior art systems.
For example, PV array 10 as shown in FIG. 51 would normally require
an additional layer of PV frame support members 131PA between
purlins 180 and PV frames 212 or as an alternative some prior art
systems allow increasing the number of purlins shown to 8 (two per
row) instead of adding another layer of structural support (thus
the purlins become the PV frame support members). The inventive
system of this embodiment however creates a parallel interlock
support system 160 which only requires connection of PV frames 212
to the three purlins 180 as shown. In other embodiments it is
desired to minimize the size of frames 212, therefore additional
purlins may be used, but still not as many prior art systems
require. In other embodiments brackets 132 are formed in different
shapes to facilitate connection to the shape of mounting surface
144. For example, some are shaped to compress a portion of an
I-shaped beam whereas others are adapted for connection to circular
pipe. Still others are formed as "legs" to allow tilting up one
side of an array 10. One skilled in the art will recognize that
there are many different types of brackets which make up the entire
scope of the inventive device. Thus, any bracket which has one
portion shaped to optimize connection to a mounting surface 144 and
another portion which is shaped to optimize connection to at least
one PV frame 212, is a suitable bracket 132 for use with the
present invention.
[0155] FIGS. 53-54 show an alternate embodiment of PV array 10
which further comprises a snap-in conduit box 195. FIG. 53 depicts
a perspective view of two interlocked PV modules 12A, 12B which are
at the end of a row. FIG. 54 shows a perspective view of conduit
box 195. Conduit box 195 snaps into slots 26A, 26B via spring clips
197. Hole 196 in the rear of conduit box 195 allows wiring from
array 10 to pass into box 195, then out through conduit 198
connected to box 195. An optional cover plate for conduit box 195,
as are typical in the art, is not shown here. Use of conduit box
195 along with PV array 10 greatly simplifies wiring since all
wiring can be routed through gaps between PV modules 12, then into
conduit box 195 and out through conduit 198 to inverters or other
system equipment. PV installers commonly fashion means for
connecting junction boxes to PV array support structures via strut
and other materials. However, a ready-made box saves time in
cutting strut and custom rigging for each job. Conduit box 195 may
also enhance the aesthetics of array 10 since it may be
manufactured to match PV modules frames. In other embodiments
conduit box 195 is more firmly attached to frames 12A, 12B by
connecting it via bolts or couplings 50j instead of spring clips
197, in a similar way to the connection of series coupling portions
as shown in the second embodiment above. In still other embodiments
conduit box is replaced by a simple plate for receiving a strain
relief or conduit coupling.
[0156] FIG. 55 depicts a perspective view of an alternate
embodiment of PV module 11 as shown in FIG. 1. A PV module 411 with
a PV laminate 420 and a frame 412 is shown. Frame 412 comprises two
frame members 413 with slots 426 on opposite sides of a laminate
back plane or base 409. Devices such as base 409, as are known in
the art, may serve to insulate a roof or provide structural support
to PV laminate 20 or both. Base 409, however, is not rigid enough
to fully support PV laminate 420, and thus frame members 413 are
glued, fastened, or otherwise adhered to base 409 or laminate 420
or both in order to provide structural support to PV module 411 and
to provide a means for interlocking the sides of an array of PV
modules 411 together. Base 409 may be adhered to the underside of
PV laminate 420. Since PV laminate 420 is supported by frame
members 413 and base 409, it may overhang frame members 413 as
shown. In another embodiment frame members 413 enclose base
409.
[0157] Other embodiments add different features. For example, one
embodiment adds a ball and detent to locking portion 104A, 104B to
prevent locking portion 104A, 104B from disengaging or working its
way free and provide a position location stop. Another provides a
quick-release handle attached to rotating portion 100. The handle
is tucked just lower than laminate 20 height when in locked mode
and can be rapidly rotated by use of a finger-hold. Such a feature
may be of use to firemen in an emergency. Another embodiment
provides a locking portion which comprises an expansion bolt. Other
embodiments provide various devices which snap into or connect to
slot 26 such as: tool holders, tools, string line holders, lights,
fasteners, cosmetic flashings, architectural features, snow guards,
debris screens, rodent screens, signs, cable clips, bird
deterrents, and electrical connector housings.
[0158] While a number of exemplary aspects and embodiments have
been discussed above, those of skill in the art will recognize
certain modifications, permutations, additions and sub-combinations
thereof. It is therefore intended that the following appended
claims and claims hereafter introduced be interpreted to include
all such modifications, permutations, additions, and
sub-combinations as are within their true spirit and scope.
* * * * *