PIVOT-FIT CONNECTION APPARATUS, SYSTEM, AND METHOD FOR PHOTOVOLTAIC MODULES

• US 20110000519A1
• Filed: 07/02/2010
• Published: 01/06/2011
• Est. Priority Date: 07/02/2009
• Status: Active Grant

• Current Assignee: Tesla Inc.
• Original Assignee: SolarCity Corporation (Tesla Inc.)
• Inventors: West, John R.
• Granted Patent: US 8,991,114 B2
• Time in Patent Office: Days
• US Class Current: 136/244
• CPC Class Codes: F16B 5/0216 the position of the plates to be connected being adjustable
• CPC Class Codes: F24S 2025/02 Ballasting means
• CPC Class Codes: F24S 25/16 Arrangement of interconnected standing structures; Standing structures having separate supporting portions for adjacent modules
• CPC Class Codes: F24S 25/20 Peripheral frames for modules
• CPC Class Codes: F24S 25/61 for fixing to the ground or to building structures
• CPC Class Codes: F24S 25/613 in the form of bent strips or assemblies of strips; Hook-like connectors; Connectors to be mounted between building-covering elements
• CPC Class Codes: F24S 25/67 for coupling adjacent modules or their peripheral frames for fixing modules or their peripheral frames to supporting elements F24S25/63
• CPC Class Codes: F24S 25/70 with means for adjusting the final position or orientation of supporting elements in relation to each other or to a mounting surface; with means for compensating mounting tolerances
• CPC Class Codes: H01L 31/048 Encapsulation of modules
• CPC Class Codes: H02S 20/23 specially adapted for roof structures
• CPC Class Codes: H02S 20/24 specially adapted for flat roofs
• CPC Class Codes: H02S 20/30 Supporting structures being movable or adjustable, e.g. for angle adjustment
• CPC Class Codes: H02S 30/10 Frame structures
• CPC Class Codes: Y02B 10/10 Photovoltaic [PV]
• CPC Class Codes: Y02E 10/47 Mountings or tracking
• CPC Class Codes: Y02E 10/50 Photovoltaic [PV] energy
• CPC Class Codes: Y10T 29/49826 Assembling or joining
• CPC Class Codes: Y10T 403/32606 Pivoted

Abstract

A system and method are disclosed for quickly and easily assembling PV modules into a PV array in a sturdy and durable manner. In examples of the present technology, the system includes various couplings having a first engaging portion adapted to engage a first PV module and a second engaging portion adapted to engage a second PV module. At least one of the engaging portions allows variable positioning of the engaged PV module along the engaging portion.

Claims

1. An array of photovoltaic modules connected together by couplings, a first coupling of said couplings comprising:

a first engaging portion adapted to engage a first photovoltaic module; and

a second engaging portion adapted to pivotally engage a second photovoltaic module along a length of a side of said second photovoltaic module, said length being substantially parallel with a plane of a laminate of said second photovoltaic module;

wherein said second engaging portion is adapted to allow variable positioning of said second photovoltaic module relative to said first coupling in a direction substantially parallel with said plane and perpendicular to said length.

2. The array of photovoltaic modules as recited in claim 1, wherein said first coupling is adapted to provide a grounding bond between said first and second photovoltaic modules.

3. The array of photovoltaic modules as recited in claim 1, wherein said second engaging portion is adapted to form a tight fit with said second photovoltaic module within a cumulative tolerance range for mating parts of −

0.010″

to +0.010″

.

4. The array of photovoltaic modules as recited in claim 1, wherein said second engaging portion is adapted to form a tight fit with said second photovoltaic module after said first coupling and said second photovoltaic module have been rotated relative to each other in a plane substantially perpendicular to said plane of said laminate and substantially parallel to said length.

5. The array of photovoltaic modules as recited in claim 1, wherein said first coupling further comprises a bracket portion for attachment to a support structure.

6. The array of photovoltaic modules as recited in claim 1, wherein said first coupling further comprises a height adjustable bracket portion for attachment to a support structure.

7. A coupling for connecting a photovoltaic module to an adjacent photovoltaic module in a photovoltaic array, said adjacent photovoltaic module comprising a frame, the coupling comprising:

a first engaging portion adapted to engage said photovoltaic module; and

a second engaging portion adapted to engage said adjacent photovoltaic module at an insertion angle greater than 2 degrees relative to a plane of said photovoltaic module, wherein at least one of said second engaging portion and said frame is adapted to flex open as at least one of said coupling and said frame is rotated from said insertion angle to a position substantially parallel with said plane.

8. The coupling as recited in claim 7, wherein said flexing open partially deforms at least a portion of at least one of said coupling and said frame.

9. The coupling as recited in claim 7, wherein said deformation is plastic.

10. The coupling as recited in claim 7, wherein said deformation is permanent.

11. The coupling as recited in claim 7, wherein said angle is greater than 5 degrees.

12. The coupling as recited in claim 7, wherein said angle is greater than 10 degrees.

13. The coupling as recited in claim 7, wherein said angle is greater than 20 degrees.

14. The coupling as recited in claim 7, wherein said coupling is further adapted to provide a ground bonding path between said frame and said coupling.

15. The coupling as recited in claim 7, wherein said coupling is further adapted for connection to said adjacent photovoltaic module in a rail-less attachment.

16. The coupling as recited in claim 7, wherein said coupling further comprises a foot bracket.

17. The coupling as recited in claim 7, wherein said frame is further adapted to receive a leveling foot.