Apparatus for forming and mounting a photovoltaic array
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.
1. A coupling for connecting to outward facing grooves in a pair of photovoltaic modules, wherein:
said coupling comprises:
(i) a center rotating portion,
(ii) a first locking portion connected to a first shaft extending through a flexible deformable retainer portion from one side of the center rotating portion, and
(iii) a second locking portion connected to a second shaft extending through a flexible deformable retainer portion from an opposite side of the center rotating portion, each of the first and second locking portions having a length along a radially extending portion and a width across said radially extending portion, said length extending substantially longer than said width and aligning in a substantially parallel manner with a longest dimension of one of said outward facing grooves in an insertion position, and wherein the first and second locking portions each comprise ridged camming surfaces thereon, and wherein the ridged camming surfaces bite into the top and bottom of the outward facing grooves to provide grounding.
2. A coupling according to claim 1 , wherein said locking portions are adapted to insert into said grooves in a direction substantially perpendicular to said longest dimension of one of said outward facing grooves.
3. A coupling according to claim 1 , wherein said length is approximately 1.2 to 3 times said width.
4. A coupling according to claim 1 , wherein said length of said first or second locking portions in said insertion position is substantially aligned with said longest dimension of one of said outward facing grooves.
5. A coupling according to claim 1 , wherein said outward facing grooves extends substantially along a length of a frame member of said first and second photovoltaic modules.
6. A coupling according to claim 1 , wherein said outward facing grooves comprise a slot.
7. A coupling according to claim 1 , wherein said coupling is not wider than a width of one of said photovoltaic modules.
8. An assembly comprising:
a pair of photovoltaic modules having outward facing grooves therein; and
a coupling for connecting to the outward facing grooves in said pair of photovoltaic modules, wherein:
said coupling comprises:
(i) a center rotating portion,
(ii) a first locking portion connected to a first shaft extending through a flexible deformable retainer portion from one side of the center rotating portion, and
(iii) a second locking portion connected to a second shaft extending through a flexible deformable retainer from an opposite side of the center rotating portion, each of the first and second locking portions having a width less than a height of an opening of said outward facing grooves and a longest dimension approximately equal to a height inside of said outward facing grooves, and
wherein the first and second locking portions each comprise ridged camming surfaces thereon, and wherein the ridged camming surfaces bite into the top and bottom of the outward facing grooves to provide grounding.
9. A coupling according to claim 8 , wherein said width is approximately 0.5 to 0.9 times said height of said opening of said outward facing grooves.
10. A coupling according to claim 8 , wherein said outward facing grooves extend the length of a frame member of said photovoltaic modules.
11. A coupling according to claim 8 , wherein said outward facing grooves comprise a locking portion stop.
12. A coupling according to claim 8 , wherein said outward facing grooves comprise a slot.