Apparatus for forming and mounting a photovoltaic array

• US 8,375,654 B1
• Filed: 02/10/2012
• Issued: 02/19/2013
• Est. Priority Date: 07/02/2009
• Status: Active Grant

• Current Assignee: Tesla Inc.
• Original Assignee: Zap Solar Incorporated
• Inventors: West, John R., Manansala, Christina C., Haenlein, Hans-Christoph
• Primary Examiner(s): Canfield, Robert
• Assistant Examiner(s): FONSECA, JESSIE T
• Application Number:
  US13/370,612
• Time in Patent Office: 375 Days
• Field of Search: 521/733, 525/822, 525/841, 525/861, 525/862, 526/98, 527/10, 136/244, 136/251, 136/252, 126/621, 126/622, 126/623, 248/220.21, 248/220.22, 248/221.11, 248/222.14, 248/222.13, 248/237
• US Class Current: 52/173.3
• CPC Class Codes: F16B 5/10 by means of bayonet connections F16B5/0092 takes precedence; fastening devices locking by rotation F16B21/02
• CPC Class Codes: F24S 2025/6006 by using threaded elements, e.g. stud bolts
• CPC Class Codes: F24S 25/10 extending in directions away from a supporting surface
• 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 25/632 Side connectors; Base connectors
• CPC Class Codes: F24S 25/636 clamping by screw-threaded elements
• CPC Class Codes: F24S 25/65 for coupling adjacent supporting elements, e.g. for connecting profiles together
• 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: H02S 20/23 specially adapted for roof structures
• CPC Class Codes: Y02B 10/10 Photovoltaic [PV]
• CPC Class Codes: Y02B 10/20 Solar thermal
• CPC Class Codes: Y02E 10/47 Mountings or tracking
• CPC Class Codes: Y02E 10/50 Photovoltaic [PV] energy
• CPC Class Codes: Y10T 403/553 Laterally inserted section
• CPC Class Codes: Y10T 403/70 Interfitted members

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.

Claims

1. A photovoltaic array comprising:

a first, second, third, and fourth photovoltaic module each comprising two or more frame members mechanically connected to a photovoltaic laminate; and

a series-parallel coupling adapted to engage with at least one of said frame members from each of said photovoltaic modules near the corners of said modules to interlock a first frame member of said first photovoltaic module with a first frame member of said second photovoltaic module in parallel, a first frame member of said third photovoltaic module with a first frame member of said fourth photovoltaic module in parallel, said first frame member of said first photovoltaic module with said first frame member of said third photovoltaic module in series, and said first frame member of said second photovoltaic module with said first frame member of said fourth photovoltaic module in series, wherein said series-parallel coupling is adapted to cut into at least a portion of a surface of at least four of said frame members to provide a ground bond between said series-parallel coupling and said photovoltaic modules.

2. The photovoltaic array of claim 1 wherein said series-parallel coupling further comprises a bracket portion.

3. The photovoltaic array of claim 1 wherein said frame members each comprise an outside surface and a groove along a substantial portion of an outside surface.

4. The photovoltaic array of claim 1 wherein said series-parallel coupling is adapted to adjust for substantially small dimensional variations between said photovoltaic modules.

5. The photovoltaic array of claim 1 wherein at least two of said photovoltaic modules are adapted to receive said series-parallel coupling after being placed in their substantially final positions on the roof.

6. The photovoltaic array of claim 1 wherein said photovoltaic modules are adapted to operate in a first mode and a second mode, all of said photovoltaic modules being substantially securely attached to a support structure in said first mode and said series-parallel coupling being substantially disengaged from said array in said second mode.