Connecting components for photovoltaic arrays

• US 9,166,524 B2
• Filed: 02/05/2015
• Issued: 10/20/2015
• Est. Priority Date: 12/13/2011
• Status: Active Grant

• Current Assignee: Tesla Inc.
• Original Assignee: SolarCity Corporation (Tesla Inc.)
• Inventors: West, Jack Raymond, Atchley, Brian, Hudson, Tyrus Hawkes, Johansen, Emil
• Primary Examiner(s): MATTEI, BRIAN DAVID
• Application Number:
  US14/615,320
• Publication Number:
  US 20150155823A1
• Time in Patent Office: 257 Days
• US Class Current: 1/1
• CPC Class Codes: E04D 1/2916 the fastening means taking hold directly on adjacent elements of the same row
• CPC Class Codes: F16M 13/022 repositionable
• CPC Class Codes: F24S 2025/801 having hollow parts with closed cross-section
• CPC Class Codes: F24S 2025/807 having undercut grooves
• CPC Class Codes: F24S 25/33 forming substantially planar assemblies, e.g. of coplanar or stacked profiles
• 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 25/632 Side connectors; Base connectors
• CPC Class Codes: F24S 25/634 Clamps; Clips
• 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 25/70 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: H02S 20/30 Supporting structures being movable or adjustable, e.g. for angle adjustment
• 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 29/49826 Assembling or joining

Abstract

The invention includes an apparatus for mounting a photovoltaic (PV) module on a structure where the apparatus includes a base portion, a stud portion, and a coupling portion. The coupling portion includes a male portion that acts as a spring under load and a clip portion that penetrates the PV module frame to create a grounding bond. The apparatus includes a lower jaw, shaped to pry open a groove, and a key portion that can compress to allow for tolerances. The invention further includes a clip with one or more tabs and one or more teeth. The invention further includes a replacement roof tile which includes a support structure with a horizontal flange, a vertical component, a horizontal component, a flashing with an upper surface and a lower surface, and a tile-shaped metal surface having a curvilinear shape that reflects the shapes of adjacent tiles.

Claims

1. A leveling foot for mounting first and second photovoltaic modules on a structure and adjusting the height of the first and second photovoltaic modules above the structure, comprising:

(a) a base portion;

(b) a stud portion extending upwardly from the base portion; and

(c) a spring coupling mounted to the stud portion, wherein the spring coupling comprises;

(i) a key portion having upper and lower jaws, and

(ii) a tongue portion, and

(iii) a grounding clip received between the upper and lower jaws of the key portion,

wherein the height of the spring coupling is adjustable with respect to the base portion to raise or lower the first and second photovoltaic modules, and

wherein the grounding clip penetrates into frames of the first and second photovoltaic modules.

2. The leveling foot of claim 1, wherein the spring coupling further comprises:

(iv) a support below the lower jaw, and

(v) a tail below the tongue portion.

3. The leveling foot of claim 2, wherein the tail is longer than the tongue portion.

4. The leveling foot of claim 1, wherein the key and tongue portions extend from opposite sides of the spring coupling.

5. The leveling foot of claim 1, wherein the key portion is shorter than the tongue portion.

6. The leveling foot of claim 1, wherein the upper and lower jaws compress together when the key portion is received into a side groove in a photovoltaic module.

7. The leveling foot of claim 1, wherein the grounding clip penetrates into frames of first and second photovoltaic modules when the first photovoltaic module is received onto the key portion of the spring coupling and the second photovoltaic module is received onto the tongue portion of the spring coupling.

8. The leveling foot of claim 1, wherein the grounding clip has teeth on opposite ends.

9. The leveling foot of claim 1, wherein the key portion is dimensioned to be received within a side groove of a first photovoltaic module and the tongue portion is dimensioned to be received within a side groove of a second photovoltaic module.

10. The leveling foot of claim 1, wherein the key portion locks into a side groove in a first photovoltaic module and prevents the first photovoltaic module from moving, and wherein the tongue portion locks into a side groove in a second photovoltaic module but permits the second photovoltaic module to move in a horizontal direction.

11. The leveling foot of claim 1, wherein the height of the spring coupling above the base portion is adjustable by rotating the stud portion with respect to the spring coupling.

12. The leveling foot of claim 11, wherein the stud portion is rotatable by accessing a tool-receiving structure on the top of the stud portion.

13. The leveling foot of claim 1, wherein the base portion has an attachment slot passing therethrough.

14. The leveling foot of claim 1, wherein both the key and tongue portions have upwardly facing ridges at their distal ends.