Pivot-fit connection apparatus, system, and method for photovoltaic modules

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.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS[0001]The present application is a continuation of U.S. application Ser. No. 12 / 830,250, entitled “Pivot-Fit Connection Apparatus, System, and Method For Photovoltaic Modules”, filed Jul. 2, 2010, which claimed to U.S. Provisional Patent Application No. 61 / 270,122, entitled “Forming and Mounting a Photovoltaic Array,” filed Jul. 2, 2009; U.S. Provisional Patent Application No. 61 / 255,004, entitled “Forming and Mounting a Photovoltaic Array: Hardware and Software Improvements,” filed Oct. 26, 2009; U.S. Provisional Patent Application No. 61 / 351,586, entitled, “Pivot-Fit Connection System, Apparatus and Method for Photovoltaic Arrays,” filed Jun. 4, 2010. Each of the above applications are incorporated by reference herein in their entirety.BACKGROUND[0002]Photovoltaic (PV) arrays are formed by mechanically linking together PV modules into an array. Most PV module coupling systems require the time-consuming use of multiple small fasteners. High pa...

AI Technical Summary

Benefits of technology

The patent describes a system and method for easily and securely assembling PV modules into a PV array. The PV modules have a groified frame with an angled groove that is connected to other components using a pivot-fit connection. A leveling foot is used to mount the PV module to, and a male component on the foot fits into the groove, allowing the module to pivot into position. The groove then grabs the module, holding it securely in place. The groove and male component provide adjustment for tolerance variations, ensuring the module is stable and durable. Overall, the system makes it easy to assemble and maintain a reliable PV array.

Problems solved by technology

Most PV module coupling systems require the time-consuming use of multiple small fasteners.

High part count and slow installation time is a major barrier to reducing PV system costs and adoption.

First, neither of these methods can adequately account for variations in the dimensions of PV modules and couplings due to manufacturing tolerances. PV modules typically vary by approximately ±0.10″ along the length and / or width dimension. When multiple modules are formed into columns in the north-south direction of the PV array, it is critical that any dimensional variations from one module in the column not carry forward to the next module in the column, as the dimensional variations will add up over the length of the column and result in significant dimensional differences from one column to the next. Likewise, the same problem exists with east-west rows of PV modules. This problem, frequently referred to as tolerance take-up, is solved in rail-based systems by spacing the modules in a column more or less from each other on top of mounting rails so that the next module in the column is properly positioned and / or by only linking modules to the rails along one axis, either east-west or north-south. However, in rail-free systems, a PV module is structurally connected to the next module in both the north-south direction and the east-west direction. Thus, if the seams between adjacent east-west modules do not line up because of compounded north-south dimensional variations, then it may be impossible to complete the installation of an array. In other systems compounded east-west variations may cause problems along the north-south axis. Press-fit and hook-type connections do not adequately address or solve the problem of tolerance variations.

Second, press-fit and hook-type connections do not provide a reliable electrical ground bond between adjacent PV modules. Hook-type connections are inherently loose-fitting and thus incapable of providing a consistent, low-resistance ground bond that will withstand weather conditions over time. Similarly, a press-fit connection does not provide a reliable ground bond unless the materials are deformed enough in the connection. In practice, too much force is required to achieve such deformation with standard PV module frame materials such as aluminum, thereby eliminating any time and cost savings that might have occurred since a heavy-duty tool would be required to deliver the force needed for the deformation.

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