Leveling foot apparatus, system, and method for photovoltaic arrays

• US 8,919,053 B2
• Filed: 07/02/2010
• Issued: 12/30/2014
• Est. Priority Date: 07/02/2009
• Status: Active Grant

• Current Assignee: Tesla Inc.
• Original Assignee: Zep Solar LLC (Tesla Inc.)
• Inventors: West, John R.
• Primary Examiner(s): LAUX, JESSICA L
• Application Number:
  US12/830,252
• Publication Number:
  US 20110000520A1
• Time in Patent Office: 1,642 Days
• Field of Search: 521/733, 525/861, 525/862, 524/60, 524/63, 524/68, 524/71, 136/243
• US Class Current: 52/173.3
• 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 apparatus 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 a leveling foot for engaging a PV module and supporting the PV module on a support structure. The leveling foot allow adjustment of the height of engaged PV modules relative to the support structure.

Claims

1. A leveling foot for use in a solar array, comprising:

(a) a base portion;

(b) a coupling portion dimensioned to engage with a first photovoltaic module on one side and with a second photovoltaic module on opposite side; and

(c) a rotatable stud connecting the coupling portion to the base portion, wherein rotation of the stud varies the distance between the coupling portion and the base portion, and wherein the rotatable stud is accessible to simultaneously vary the heights of the first and second photovoltaic modules after the first and second photovoltaic modules are engaged with the coupling portion;

wherein the rotatable stud is accessible from above the first and second photovoltaic modules to simultaneously vary the heights of the first and second photovoltaic modules after the first and second photovoltaic modules have been engaged with the coupling portion.

2. The leveling foot of claim 1, wherein a top end of the rotatable stud has a tool interface.

3. The leveling foot of claim 2, wherein the tool interface is a tool-receiving recess.

4. The leveling foot of claim 1, wherein the height of the coupling portion on the base portion is continuously adjustable over a range of different heights.

5. The leveling foot of claim 1, wherein both the coupling portion and the base portion extend fully across a gap between the first and second photovoltaic modules.

6. The leveling foot of claim 1, wherein the base portion extends from a position adjacent to the first photovoltaic module to a position beneath the second photovoltaic module.

7. The leveling foot of claim 1, wherein the stud rotates around a vertical axis.

8. The leveling foot of claim 1, wherein one or both ends of the stud are threaded.

9. The leveling foot of claim 8, wherein the coupling portion has a threaded hole passing therethrough.

10. The leveling foot of claim 1, further comprising a slot passing through the base portion of the leveling foot and a fastener received through the slot to secure the base portion to a roof, wherein a vertical axis passing through the fastener is parallel to a vertical axis passing through the rotatable stud, and wherein the vertical axis passing through the fastener does not pass through the coupling portion.

11. The leveling foot of claim 1, wherein the coupling portion has a tongue on opposite sides.

12. The leveling foot of claim 1, wherein the coupling portion can be slidably moved to different positions along the length of the sides of the first and second photovoltaic modules.

13. The leveling foot of claim 1, wherein opposite sides of the coupling portion are dimensioned to be receivable into side grooves in the first and second photovoltaic modules.

14. The leveling foot of claim 13, wherein the coupling portion is rotated into a locked position within the side grooves.

15. The leveling foot of claim 13, wherein the first and second photovoltaic modules are pivoted downwardly into locked positions on opposite sides of the coupling portion.

16. The leveling foot of claim 1, wherein the height of the coupling portion can be adjusted after the first photovoltaic module has been connected to the coupling portion, but prior to the second photovoltaic module being connected to the coupling portion.

17. A solar array comprising:

(a) a first photovoltaic module;

(b) a second photovoltaic module; and

(c) a leveling foot connecting the first and second photovoltaic modules together, wherein the leveling foot comprises;

(i) a base portion;

(ii) a coupling portion dimensioned to engage with the first photovoltaic module on one side and with the second photovoltaic module on opposite side; and

(iii) a rotatable stud connecting the coupling portion to the base portion, wherein rotation of the stud varies the distance between the coupling portion and the base portion, and wherein the rotatable stud is accessible to simultaneously vary the heights of the first and second photovoltaic modules after the first and second photovoltaic modules have been connected to the coupling portion;

wherein the rotatable stud is accessible from above the first and second photovoltaic modules to simultaneously vary the heights of the first and second photovoltaic modules after the first and second photovoltaic modules have been engaged with the coupling portion.

18. The solar array of claim 17, wherein a top end of the rotatable stud has a tool interface.

19. The solar array of claim 17, wherein both the coupling portion and the base portion extend fully across a gap between the first and second photovoltaic modules.

20. The solar array of claim 17, wherein the base portion extends from a position adjacent to the first photovoltaic module to a position beneath the second photovoltaic module.

21. The solar array of claim 17, further comprising a slot passing through the base portion of the leveling foot and a fastener received through the slot to secure the base portion to a roof, wherein a vertical axis passing through the fastener is parallel to a vertical axis passing through the rotatable stud, and wherein the vertical axis passing through the fastener does not pass through the coupling portion.

22. The solar array of claim 17, wherein the coupling portion can be slidably moved to different positions along the length of the sides of the first and second photovoltaic modules.

23. The solar array of claim 17, wherein opposite sides of the coupling portion are dimensioned to be receivable into side grooves in the first and second photovoltaic modules.

24. The solar array of claim 23, wherein the first and second photovoltaic modules are pivoted downwardly into locked positions on opposite sides of the coupling portion.

25. The solar array of claim 17, wherein the height of the coupling portion can be adjusted after the first photovoltaic module has been connected to the coupling portion, but prior to the second photovoltaic module being connected to the coupling portion.

26. The leveling foot of claim 17, wherein the second photovoltaic module can be removed and replaced without adjusting the height of the coupling portion above the base portion.