Photovoltaic module interlock system

Abstract

Systems and methods of the present disclosure can include an interlocking system. The interlocking system can include a plate defining a first aperture, a second aperture, and a third aperture; a spacer removably coupled to the plate and extending at least partially through the second aperture, the spacer including a first adjustable tab and a second adjustable tab, the spacer movable through the second aperture via the first adjustable tab and the second adjustable tab; a first electrical connector coupled to the plate and extending at least partially through the first aperture, the first electrical connector configured to rotate to form an electrical connection; and a second electrical connector coupled to the plate and extending at least partially through the third aperture, the second electrical connector configured to rotate to form an electrical connection.

Description

Technical Field

[0001] This disclosure relates primarily to photovoltaic module installation apparatus, and more particularly to photovoltaic module interlocking systems. Background Technology

[0002] Photovoltaic modules, such as solar panels, can be installed on structures such as roofs. Reliably performing the installation in a way that addresses factors such as the proper alignment, stability, orientation, and electrical connections of the photovoltaic modules can be challenging. Summary of the Invention

[0003] At least one aspect of this disclosure relates to an interlocking system for a photovoltaic module, comprising: a plate defining a first hole, a second hole, and a third hole; a spacer removably coupled to the plate and extending at least partially through the second hole, the spacer including a first adjustable tab and a second adjustable tab, the spacer being movable through the second hole via the first adjustable tab and the second adjustable tab; a first electrical connector coupled to the plate and extending at least partially through the first hole, the first electrical connector being configured to rotate to form an electrical connection; and a second electrical connector coupled to the plate and extending at least partially through the third hole, the second electrical connector being configured to rotate to form an electrical connection.

[0004] In various embodiments, the spacer may include a first end having a top surface and a bottom surface opposite to the top surface, a first adjustable tab extending from the top surface at a first angle between five and twenty-five degrees and including an end value; and a second adjustable tab extending from the bottom surface at a second angle between five and twenty-five degrees and including an end value.

[0005] In various embodiments, the spacer may include a second end opposite the first end, the height and width of which are greater than the height and width of the second hole. The plate may include a conductive material. The plate may have a length between 130 and 150 millimeters (mm) including the end values, and a height between 25 and 45 millimeters including the end values. The spacer may include an electrically insulating material.

[0006] In various embodiments, the second hole may be located between the first hole and the third hole, the first hole and the third hole being equidistant from the second hole, and at least one of the first electrical connector and the second electrical connector may include at least one protrusion configured to be inserted into the plate when the first electrical connector and the second electrical connector are rotated.

[0007] In various embodiments, at least one of the first electrical connector and the second electrical connector has a first position, a second position, and a third position, the first position corresponding to an unrotated state, the second position corresponding to a partially rotated state, and the third position corresponding to a rotated state. The first electrical connector and the second electrical connector form an electrical connection in the third position. At least one of the first electrical connector and the second electrical connector may include a first indicator corresponding to the first position, a second indicator corresponding to the second position, and a third indicator corresponding to the third position. The first indicator extends along a first axis, and the third indicator extends along a third axis, which intersects the first axis at an angle between 88 and 92 degrees, including the endpoints.

[0008] At least one aspect of this disclosure relates to a modular system. The modular system may include a plurality of modules configured to generate electricity; and at least one interlocking device configured to isolate and electrically connect at least a portion of the plurality of modules. The interlocking device may include: a plate defining a first hole, a second hole, and a third hole; a spacer coupled to the plate and capable of extending at least partially and moving through the second hole, the spacer contacting at least two of the plurality of modules and configured to isolate at least two of the plurality of modules; a first electrical connector coupled to the plate and extending at least partially through the first hole and configured to electrically connect at least a portion of the plurality of modules; and a second electrical connector coupled to the plate and extending at least partially through the second hole and configured to electrically connect at least a portion of the plurality of modules.

[0009] In various embodiments, the first electrical connector includes a first end configured to contact a first module among a plurality of modules; and a second end configured to face a second module among the plurality of modules. The second electrical connector may include a first end configured to contact a third module among the plurality of modules; and a second end configured to face a fourth module among the plurality of modules. In various embodiments, the third module is identical to the first module, or the second module is identical to the fourth module.

[0010] In various embodiments, the first end of the first electrical connector and the first end of the second electrical connector may have an angle between 85 and 95 degrees, including the end value, the angle limiting the rotation of the first and second electrical connectors to no more than 88 to 92 degrees, including the end value. At least one of the first and second electrical connectors has a first position, a second position, and a third position, the first position corresponding to an unrotated state, the second position corresponding to a partially rotated state, and the third position corresponding to a rotated state. At least one interlocking device may electrically connect at least a portion of a plurality of modules in response to at least one of the first and second electrical connectors being in the third position.

[0011] In various embodiments, at least one of the second ends of the first electrical connector and the second electrical connector may include a first indicator, a second indicator, and a third indicator, the first indicator corresponding to a first position, the second indicator corresponding to a second position, and the third indicator corresponding to a third position, and the first indicator extending along a first axis, the third indicator extending along a third axis, the third axis intersecting the first axis at an angle between 88 and 92 degrees and including end values.

[0012] In various implementations, the spacer may be in a first position, a second position, or removed from at least one interlocking device, with the spacer in contact with two of the plurality of modules in the first and second positions.

[0013] In various embodiments, the plate may include a top surface including a first mark aligned with the midpoint of a first hole, a second mark aligned with a first edge of a second hole, a third mark aligned with the midpoint of the second hole, a fourth mark aligned with a second end of the second hole, and a fifth mark aligned with the midpoint of a third hole. The plate may include a rear surface continuous with the top surface, the rear surface including a plurality of protrusions configured to facilitate alignment of at least one interlocking device with at least one of a plurality of modules.

[0014] At least one aspect of this disclosure relates to an interlocking device. The interlocking device may include a plate defining a first opening, a second opening, and a third opening, the second opening being located between the first and third openings; and a spacer capable of extending and moving through the second opening. The spacer may be coupled to the plate and is capable of extending and moving at least partially through the second opening. The spacer may include a first surface, a first branch extending from the first surface, a second surface, and a second branch extending from the second surface. The first and second branches may have a first state and a second state, the first and second branches being closer to each other in the second state than in the first state, and the spacer being capable of moving through the second opening when the first and second branches are in the second state.

[0015] In various embodiments, the spacer comprises a flexible electrically insulating material, and the first and second branches are configured to be pushed together to adjust from a first state to a second state. The interlocking device may include at least one electrical connector coupled to a plate and extending at least partially through at least one of a first opening and a third opening, the at least one electrical connector being rotatable to form an electrical connection. Attached Figure Description

[0016] Details of one or more embodiments are set forth in the accompanying drawings and the description below. Other features, aspects, and advantages of this disclosure will become apparent from the description, drawings, and claims, wherein: Figure 1 It is a block diagram of an example system including an example interlocking system; Figure 2 This is a top view of the example system; Figure 3 This is a perspective view of an example interlocking system; Figure 4 yes Figure 3 Rear view of the interlocking system; Figure 5 yes Figure 3 Another perspective view of the interlocking system; Figure 6 yes Figure 3 Another perspective view of the interlocking system; Figure 7 yes Figure 3 Exploded view of the interlocking system; Figure 8 yes Figure 3 A cross-sectional view of the interlocking system; Figure 9A yes Figure 3 A top view of the location of an example interval component in an interlocking system.

[0017] Figure 9B This is a top view of the location of the example interval component in the example interlocking system; Figure 10A yes Figure 2 A perspective view of the system; Figure 10B It is a perspective view of an example system that includes an example interlocking system; Figure 11 This is a partial schematic side view of an example interlocking system; Figure 12 This is a partial schematic side view of an example interlocking system; Figure 13 This is a partial schematic side view of an example interlocking system; and Figure 14 This is a sample installation method for the sample system. Detailed Implementation

[0018] Before turning to the accompanying drawings, which illustrate certain exemplary embodiments in detail, it should be understood that this disclosure is not limited to the details or methods set forth in the specification or shown in the drawings. It should also be understood that the terminology used herein is for illustrative purposes only and should not be considered restrictive.

[0019] The interlocking system according to this disclosure can separate and electrically connect modules (e.g., panels, batteries, etc.), which can be photovoltaic (PV) modules (e.g., solar panels, etc.) for converting sunlight into electricity. The interlocking system can facilitate module installation. It can separate individual modules to mitigate overheating. Module separation also takes into account the thermal expansion and wind load dynamics of the modules to reduce damage. The interlocking system can electrically connect rows (e.g., in a row, in a series, etc.) of modules to each other, for example, grounding the rows of modules, thereby protecting the modules from fault currents and eliminating static electricity, thus reducing the risk of electric shock and overheating. The interlocking system according to this disclosure simplifies the module installation process and ensures sufficient spacing between modules.

[0020] The interlocking system may include a spacer component to ensure sufficient spacing between modules. The spacer may be located between at least two modules to separate them, and at least two modules may contact the spacer. The interlocking system may be placed between two modules, and the spacer may be positioned based on the construction of the module closest to the interlocking system. The spacer may engage with the contacting module.

[0021] The interlocking system may include electrical connectors that electrically connect the first module and the second module. These electrical connectors may provide module-to-module grounding along a row of modules and may electrically connect each module in the row.

[0022] Conventional interlocking systems may not include spacers and require specific tools for installing electrical connectors, thus increasing installation difficulty and time. For example, technicians (e.g., workers, engineers, etc.) installing modules and interlocking systems may use techniques or indicators to precisely align and space modules, further increasing installation time. The system's connectors may be over-rotated by tools, causing them to exert greater forces on the modules and increasing strain and stress on the interlocking system. Conventional interlocking systems may provide structures for at least a portion of the module's load and / or bear at least a portion of the module's load. This results in these components being larger and / or having greater mass, making manufacturing more difficult and expensive.

[0023] The interlocking system according to this disclosure facilitates electrical connections between modules and isolates them so that they do not come into contact with each other. The interlocking system can be removably coupled to the modules and includes spacers with at least three positions. The spacers can be positioned according to the position of the modules relative to the interlocking system. For example, for an interlocking system positioned between three modules, the spacers are in a first position. The spacers can improve module installation efficiency by defining physical space between modules rather than providing, for example, rulers. For example, the spacers can provide mechanical stops for movement of the modules relative to the interlocking components to provide a mechanical response indicating correct alignment. The interlocking system can include at least one electrical connector for rotating and connecting one module to another. The electrical connector can rotate without specific tools and can include indicators to facilitate the installation of the electrical connector, thereby improving the efficiency of the installation process. The electrical connector can also ground the modules along a row of modules. Compared to conventional systems, the interlocking system according to this disclosure can be smaller and have fewer parts, thereby reducing weight and manufacturing complexity.

[0024] Figure 1 System 100 (e.g., a modular system, a solar panel system, a photovoltaic module system, etc.) is depicted. System 100 may include at least one module 102 (e.g., a photovoltaic module, panel, sub-component, section, unit, array element, etc.). Module 102 may be a PV module and may use solar cells (e.g., PV cells, etc.) to convert sunlight into electricity. Solar cells can generate current through the photovoltaic effect when exposed to sunlight and can be formed from semiconductor materials such as silicon. Module 102 can supply power to, for example, the power grid, batteries, inverters, electronic devices, etc. Module 102 can generate direct current (DC) and can supply DC power to an inverter to convert it into alternating current (AC). The AC power can then be provided to power electronic devices, such as commercial or household appliances (e.g., computers, refrigerators, telephones, etc.).

[0025] Module 102 can generate electricity by absorbing sunlight and can be placed and positioned to receive sunlight. For example, module 102 can be placed on the roof of a house or building or any other angled surface to maximize the sunlight exposure of module 102. In various embodiments, the angle of module 102 can be adjusted based on the season. For example, the angle of module 102 relative to the ground can be increased in winter to capture a lower solar angle and decreased in summer to capture a higher solar angle.

[0026] System 100 may include at least one interlocking system 104 (e.g., attachment, circuit interlock, interlocking device, etc.). Interlocking system 104 may be used for modules 102. Interlocking system 104 may be positioned between modules 102 and configured to ensure proper alignment between modules 102 and provide conduits to electrically (e.g., in series) connect rows of modules 102 (e.g., at least a portion of modules 102) in system 100. Interlocking system 104 may space modules 102 to allow airflow, provide space between modules 102 for thermal expansion, and ground modules 102 to prevent electrical faults and reduce fire and electric shock hazards. For example, if there is no proper spacing between modules 102, one module 102 may cast a shadow on another module 102, thereby reducing the energy output of the other module 102. Furthermore, the interlocking system 104 spaced between modules 102 may reduce mechanical stress on system 100 and mitigate wind buoyancy that could damage or displace modules 102. Interlocking system 104 provides a robust electrical connection between modules 102, reducing the risk of loose or accidental disconnection and simplifying the electrical connection process of modules 102, thereby improving the efficiency of system 100 installation. Specifically, interlocking system 104 can electrically connect rows of modules 102, grounding each row of modules 102 in system 100. For example, each row of modules 102 can be electrically coupled to a grounding wire to ground each row of modules 102. Interlocking system 104 may not bear any load from modules 102.

[0027] System 100 can be installed on a roof, on a sloping frame on the ground, or on a raised surface. For mounting system 100, brackets (e.g., rails) or support structures (e.g., decks) can be installed, and modules 102 can be placed on and coupled to the mounting brackets or structures. When modules 102 are coupled to the mounting brackets, interlocking systems 104 can be placed between modules 102. For example, first module 102 and second module 102 can be placed on mounting brackets, and first interlocking systems 104 can be positioned to contact first module 102 and second module 102. First interlocking systems 104 can isolate first module 102 and second module 102, and electrically connect first module 102 and second module 102.

[0028] Figure 2 A top view depicting the arrangement of module 102 is provided. Module 102 can be mounted on a rack (e.g., frame, mounting base, angled surface, etc.) and can be... Figure 2Positioned as shown. Module 102 can form an array 202. Array 202 may include a surface 204 located on the periphery of array 202 (e.g., outer edge). For example, surface 204 may be a surface of module 102 that does not contact another module 102. Surface 204 may include at least one screw 206 (e.g., fastener, threaded rod, clamp, etc.) to couple module 102 to a rack. Module 102 may include at least one frame 207 (e.g., boundary, etc.) extending around module 102. Frame 207 may provide structural support for module 102 and protect the edges of module 102 from damage. Frame 207 may include at least one of ridges, holes, recesses, and other components to mount module 102 to a rack and other devices or systems, such as interlocking system 104.

[0029] At least one interlocking system 104 can be placed at a corner of module 102. For example, interlocking system 104 can be placed at points 208, 210, 212, and 214, as shown below. Figure 2 As shown. The interlocking system 104 can be placed after at least two modules 102 have been installed. For example, system 100 may include a first module 102 that can be installed to the rack first, followed by a second module 102. The interlocking system 104 at point 208 can be installed and positioned to contact the first module 102 and the second module 102. After the first module 102 and the second module 102 have been placed, other modules 102 can be coupled to the rack, and the interlocking system 104 can be placed and attached after the other modules 102 have been installed to the rack. For example, after the third module 102 adjacent to the second module 102 has been placed, the interlocking system 104 can be positioned between the second module 102 and the third module 102. The interlocking system 104 can contact and be coupled to the frame 207. The interlocking system 104 can contact the surface 204, for example, at point 212.

[0030] System 100 may include at least one row of modules 102. For example... Figure 2 As shown, module 102 may include a first row 216, a second row 218, and a third row 220. Module 102 may be grounded along the rows. For example, module 102 included in the first row 216 may be electrically coupled via an interlocking system 104 and may be electrically coupled to at least one ground wire. In various embodiments, system 100 includes a ground wire, and each of the first row 216, the second row 218, and the third row 220 is electrically coupled to that ground wire, such that each of the first row 216, the second row 218, and the third row 220 is grounded.

[0031] Figures 3 to 8 Various views of an example interlocking system 104 according to various embodiments of the present disclosure are depicted. The interlocking system 104 isolates and is electrically connected to module 102.

[0032] The interlocking system 104 may include at least one plate 302 (e.g., component, sheet, panel, etc.). Plate 302 may be formed of a material including at least one of the following: metal, ceramic, plastic, or any other material. Plate 302 may be formed of a conductive material. For example, plate 302 may be formed of aluminum. Plate 302 may have a length between 130 (e.g., 130) and 150 (e.g., 150) millimeters (mm) including the end values, and a height between 25 (e.g., 25) and 45 (e.g., 45) millimeters (mm) including the end values. Plate 302 may contact at least one module 102. Plate 302 may have a rectangular shape.

[0033] Plate 302 may include at least one end. Plate 302 may include a first end 304 and a second end 306 opposite to the first end 304. Plate 302 may extend from the first end 304 to the second end 306 and may include a midpoint 308 between the first end 304 and the second end 306. Plate 302 may define at least one hole (e.g., an opening). Plate 302 may include (e.g., define) a first hole 310, a second hole 312, and a third hole 314. The second hole 312 may be located at the midpoint 308 such that the distance from the second hole 312 to the first end 304 and the second end 306 is equal. In various embodiments, the second hole 312 is offset from the midpoint 308. The second hole 312 may be located between the first hole 310 and the third hole 314. In various embodiments, the first hole 310 and the third hole 314 are located on plate 302 at different distances from the second hole 312. The first hole 310 can be located between the first end 304 and the second hole 312, and the third hole 314 can be located between the second end 306 and the second hole 312.

[0034] The second hole 312 may have a generally rectangular shape and a width between 9 (e.g., nine) and 15 (e.g., fifteen) mm, including the end values, and a height between 20 (e.g., twenty) and 30 (e.g., thirty) mm, including the end values. The first hole 310 and the third hole 314 may have the same shape. The first hole 310 and the third hole 314 may have curved edges and may have a height smaller than that of the second hole 312 and a width larger than that of the second hole 312. The shape of the first hole 310 and the third hole 314 may include a circle and curved edges extending from the circle. The diameter of the circle may be between 10 (e.g., ten) and 20 (e.g., twenty) mm, including the end values. The curved edges of the first hole 310 and the third hole 314 may have a radius between 1 (e.g., one) and 8 (e.g., eight) mm, including the end values. The curved edges of the first hole 310 and the third hole 314 may have a height between 8 and 16 (e.g., sixteen) mm, including the end values.

[0035] Plate 302 may include at least one surface. Plate 302 may include a top surface 315. Top surface 315 may include at least one mark (e.g., indicator, symbol, etc.). Top surface 315 may include a first mark 316 aligned with the midpoint (e.g., center) of the first hole 310. The first mark 316 may be aligned with the midpoint 308. Second hole 312 may include at least one edge. Second hole 312 may include a first edge 318 and a second edge 702 opposite to the first edge 318 (e.g.,...). Figure 7 (As shown). The top surface 315 may include a second mark 322 aligned with the first edge 318, a third mark 324 aligned with the midpoint (e.g., midpoint 308) of the second hole 312, a fourth mark 326 aligned with the second edge 702, and a fifth mark 328 aligned with the midpoint of the third hole 314. The second mark 322, the third mark 324, and the fourth mark 326 may be used to separate modules 102. For example, the space between the first module 102 and the second module 102 may be defined by the distance between the second mark 322 and the fourth mark 326.

[0036] Reference Figure 4 Plate 302 may include a rear surface 402 continuous with top surface 315. Plate 302 may include a front surface 330 opposite to rear surface 402. First hole 310, second hole 312, and third hole 314 may extend from rear surface 402 to front surface 330. Rear surface 402 may include at least one protrusion (e.g., raised surface, extension). Rear surface 402 may include at least one first protrusion 332 and at least one second protrusion 334. First protrusion 332 and second protrusion 334 may extend from rear surface 402. First protrusion 332 and second protrusion 334 may define the thickness of plate 302, which may be between 9 and 16 mm and include end values. First protrusion 332 and second protrusion 334 may contact at least one module 102 and may facilitate alignment and attachment of interlocking system 104 to at least one module 102. First protrusion 332 and second protrusion 334 may contact frame 207 of module 102. In various embodiments, the first protrusion 332 and the second protrusion 334 are hooked onto or inserted into the frame 207 of at least one module 102. For example, the first protrusion 332 and the second protrusion 334 may engage with the frame 207 of the module 102.

[0037] Plate 302 may include a bottom surface 336 opposite to the top surface 315. The bottom surface 336 may be continuous with the rear surface 402. A first protrusion 332 may be located on the rear surface 402 and closer to the top surface 315 than the bottom surface 336, and a second protrusion 334 may be closer to the bottom surface 336 than the top surface 315. There may be multiple first protrusions 332, such as... Figure 4As shown, the second protrusion 334 can be located between the first end 304 and the first hole 310, between the first hole 310 and the second hole 312, between the second hole 312 and the third hole 314, and between the third hole 314 and the second end 306. The second protrusion 334 can be a plurality of second protrusions 334, and can be located between the first end 304 and the first hole 310, between the first hole 310 and the second hole 312, between the second hole 312 and the third hole 314, and between the third hole 314 and the second end 306.

[0038] The first protrusion 332 and the second protrusion 334 may have a height between 3 (e.g., three) and 5 mm. In various embodiments, the first protrusion 332 and the second protrusion 334 may have the same height or different heights. The distance between the first protrusion 332 and the second protrusion 334 on the rear surface 402 may be between 4 (e.g., four) and 9 mm, including the end value.

[0039] Plate 302 may include a third protrusion 338 extending from rear surface 402 and contacting the second protrusion 334. In various embodiments, the third protrusion 338 may be integrally formed with or included in the second protrusion 334. The third protrusion 338 may be located between bottom surface 336 and the second protrusion 334 and may have a shorter length than the first protrusion 332 and the second protrusion 334. The third protrusion 338 may mate with frame 207 of module 102 and is configured to attach interlocking system 104 to at least one frame 207 of module 102. The distance between the third protrusion 338 and bottom surface 336 may be between 2 (e.g., two) and 6 (e.g., six) mm and includes end values. The first protrusion 332, the second protrusion 334, and the third protrusion 338 may mate with frame 207 and be at least partially inserted into frame 207. The first protrusion 332, the second protrusion 334 and the third protrusion 338 can facilitate the attachment of the interlocking system 104 to the module 102.

[0040] The interlocking system 104 may include at least one spacer 340 (e.g., a spacer assembly). The spacer 340 may contact module 102 and is configured to space modules 102 apart. The spacer 340 may contact at least two modules 102 to space them apart. The spacer 340 may ensure that modules 102 are properly spaced and simplify the installation process of modules 102. In various embodiments, the spacer 340 may slide against the frame 207 of module 102. The interlocking system 104 and the spacer 340 may contact the first module 102 and the second module 102, and the interlocking system 104 and the spacer 340 may align and space the first module 102 and the second module 102. When the spacer 340 engages with the frame 207 of module 102, at least a portion of the spacer 340 may mate with or be inserted into the frame 207 of module 102. The spacer 340 may be formed of a material such as plastic, ceramic, metal, or any other material. The spacer 340 may be formed of a flexible (e.g., plastic) material. The spacer 340 may be formed of an electrically insulating material such that current does not pass through the spacer 340. The spacer 340 may be formed of a flexible electrically insulating material. The spacer 340 may define a first axis A1 and extend along it.

[0041] Spacer 340 may be coupled to plate 302 and extends at least partially through second hole 312. Spacer 340 may be removably coupled to plate 302. Spacer 340 may extend at least partially through second hole 312 and may move through second hole 312. For example, spacer 340 may move between multiple locations, such as at least... Figure 9A As shown (and further described herein). The spacer 340 can be moved, or removed, between at least a first position 901 and a second position 903. In the first position 902 and the second position 903, the spacer 340 can contact both modules 102. For example, at point 208, the spacer 340 can be in the second position 903; at point 210, the spacer 340 can be in the second position 903; and at points 212 and 214, the spacer 340 can be in the first position 901. After the interlocking system 104 is in place, the spacer 340 can be removed from the interlocking system 104. As another example, Figures 3 to 6 and Figure 8 The interlocking system 104 shown can be illustrated with spacer 340 in the second position 903. In various embodiments, spacer 340 can contact four modules 102.

[0042] As another example, see again Figure 2The first row 216 can be offset from the second row 218 and the third row 220. The second row 218 and the third row 220 can be aligned. For the interlocking system 104 located between the offset rows of modules 102, the interlocking system 104 can be in a first position 901 or a second position 903. For the interlocking system 104 located between the aligned rows of modules 102, the interlocking system 104 can be in a second position 903.

[0043] The spacer 340 may include at least one end. The spacer 340 may include a first end 342 and a second end 344 opposite to the first end 342. The spacer 340 may include a midpoint 401 (at least at...). Figure 4 (As shown in the diagram), midpoint 401 is located between the first end 342 and the second end 344. In both the first position 901 and the second position 903, the second end 344 can contact the plate 302. For example, the spacer 340 can be removed from the interlocking system 104 and reversed, such that the first end 342 extends between the module 102 above the interlocking system 104 or between the interlocking system 104 and the module it contacts. In the first position 901, the second end 344 can contact the rear surface 402, while in the second position 903, the second end 344 can contact the front surface 330. The position of the spacer 340 can be determined before the interlocking system 104 is installed with the module 102. For example, the spacer 340 can be set in either the first position 901 or the second position 903 before installation. The spacer 340 can be removed after the interlocking system 104 is installed.

[0044] The height and width of the second end 344 may be greater than the height and width of the first end 342. The height and width of the second end 344 may also be greater than the height and width of the second hole 312, allowing the second end 344 to pass through the second hole 312 without moving (e.g., moving). The height and width of the first end 342 may be less than the height and width of the second hole 312, and the spacer 340 can be removed from the plate 302 (e.g., moved to a position where it is not in contact with the plate 302) by moving the first end 342 through the second hole 312. For example, the spacer 340 can be removed from the interlocking system 104 after the module 102 has been positioned to contact the spacer 340.

[0045] In various embodiments, the width of the spacer 340 may decrease from the second end 344 to the first end 342. For example, the width of the spacer 340 at the midpoint 401 may be less than the width at the second end 344 and greater than the width at the first end 342. In various embodiments, the first end 342 of the spacer 340 may be tapered.

[0046] The first end 342 of the spacer 340 may include at least one surface. The first end 342 may include a top surface 346 and a bottom surface 403 opposite to the top surface 346. The spacer 340 may include at least one adjustable tab (e.g., a fork, tab, member, extension, etc.). The spacer 340 may include a first adjustable tab 404 extending from the top surface 346 at an angle (e.g., a first angle) between 5 (e.g., five) and 25 (e.g., twenty-five) degrees relative to the top surface 346, including the end value. Figure 8 As shown. The spacer 340 may include a second adjustable tab 406 that extends from the bottom surface 403 at an angle between 5 and 25 degrees, including an end value (e.g., a second angle). For example, the second adjustable tab 406 may extend in the opposite direction to the first adjustable tab 404. The first adjustable tab 404 may extend away from the top surface 346 and the bottom surface 403, and the second adjustable tab 406 may extend away from the bottom surface 403 and the top surface 346. The midpoint 401 of the spacer 340 may be located on the first adjustable tab 404 and extend from the first adjustable tab 404 to the second adjustable tab 406. In various embodiments, the first adjustable tab 404 and the second adjustable tab 406 may extend toward a first end 342.

[0047] The first adjustable tab 404 and the second adjustable tab 406 can be adjusted (e.g., moved) toward each other to move the spacer 340 to different positions. For example, to move the spacer 340 through the second hole 312 to change the spacer 340 between a first position 901 and a second position 903 or to remove the spacer 340 from the plate 302, the first adjustable tab 404 and the second adjustable tab 406 are adjusted such that the angle between the first adjustable tab 404 and the second adjustable tab 406 decreases. The first adjustable tab 404 can be adjusted from a 25-degree angle to 0 degrees relative to the top surface 346, and the second adjustable tab 406 can be adjusted from a 25-degree angle to 0 degrees relative to the bottom surface 403 to move the spacer 340. The first adjustable tab 404 and the second adjustable tab 406 can be pushed together to adjust the angle. The spacer 340 may be formed of a flexible electrically insulating material, such that the first adjustable tab 404 and the second adjustable tab 406 can be moved and pushed together while maintaining electrical insulation of the spacer 340. The first adjustable tab 404 and the second adjustable tab 406 may be configured to be actuated (e.g., bent, moved) to change the position of the spacer 340 or remove the spacer 340 from the plate 302.

[0048] For example, to change the spacer 340 from a first position 901 to a second position, the first adjustable tab 404 and the second adjustable tab 406 can be pushed together to move the spacer 340 through the second hole 312, thereby preventing the spacer 340 from contacting the plate 302. The spacer 340 can then be flipped (e.g., reversed) and moved back (e.g., reinserted) through the second hole 312 until the second end 344 contacts the spacer 340. Thus, the second end 344 can contact the front surface 330 in the second position 903 and the rear surface 402 in the first position 901. To remove the spacer 340, the first adjustable tab 404 and the second adjustable tab 406 can be pushed together to move the spacer 340 through the second hole 312.

[0049] The first adjustable tab 404 and the second adjustable tab 406 can have at least one state. The first adjustable tab 404 and the second adjustable tab 406 can have a first state and a second state. The first adjustable tab 404 and the second adjustable tab 406 can be closer to each other and to the first axis A1 in the second state than in the first state. To move the spacer 340, the first adjustable tab 404 and the second adjustable tab 406 can move from the first state to the second state. The angles of the first adjustable tab 404 and the second adjustable tab 406 relative to the top surface 346 and the bottom surface 403 can be smaller in the second state than in the first state.

[0050] In a first state, the first adjustable tab 404, the second adjustable tab 406, and the second end 344 can mitigate movement of the spacer 340. For example, in the first state, the first adjustable tab 404, combined with the second adjustable tab 406, can have a height higher than the second hole 312, and in various embodiments, this height can be equal to the height of the second end 344. At least one of the second end 344, the first adjustable tab 404, and the second adjustable tab 406 can contact the plate 302 to mitigate movement. For example, in a first position 901 and a second position 903, the plate 302 can be sandwiched (e.g., in contact) between the second end 344, the first adjustable tab 404, and the second adjustable tab 406.

[0051] In the second state, the first adjustable tab 404 and the second adjustable tab 406 allow the spacer 340 to move through the second hole 312, and the spacer 340 can be moved to different positions (e.g., first position 901, second position 903, removed). To change from the first state to the second state, the first adjustable tab 404 and the second adjustable tab 406 can be pushed together simultaneously by manual (e.g., external) force (e.g., towards the first axis A1). To maintain the second state to move the spacer 340, the manual force on the first adjustable tab 404 and the second adjustable tab 406 can be maintained such that the angles of the first adjustable tab 404 and the second adjustable tab 406 with the top surface 346 and the bottom surface 403 are respectively maintained at, for example, 0 degrees. Without external force, the first adjustable tab 404 and the second adjustable tab 406 can remain in the first state or return to the first state.

[0052] The spacer 340 may include a body 345. A second end 344 may be coupled to or integrally formed with the body 345, and the width of the body 345 may be less than the width of the second end 344, the top surface 346, and the bottom surface 403. The top surface 346, the bottom surface 403, and the second end 344 may be continuous with the body 345. The top surface 346, the bottom surface 403, the first adjustable tab 404, and the second adjustable tab 406 may extend away from the body 345 such that at least one of the top surface 346, the bottom surface 403, the first adjustable tab 404, and the second adjustable tab 406 can slide against and engage with the frame 207. The spacer 340 may include a space between the first adjustable tab 404 and the body 345, and a space between the second adjustable tab 406 and the body 345, such that at least a portion of the first adjustable tab 404 and the second adjustable tab 406 does not contact the body 345.

[0053] In various embodiments, a first adjustable tab 404 and a second adjustable tab 406 extend from the body 345. For example, the first adjustable tab 404 and the second adjustable tab 406 contact the body 345. The first adjustable tab 404 may be located between the top surface 346 and the bottom surface 403 and extend toward a first end 304. The second adjustable tab 406 may be located between the top surface 346 and the bottom surface 403 and extend toward a second end 306. In this embodiment, the first adjustable tab 404 and the second adjustable tab 406 can be pushed toward the midpoint 308 to move the spacer 340. In this embodiment, the width of the spacer 340 and the second hole 312 can be increased, and the height of the spacer 340 and the second hole 312 can be decreased.

[0054] In various embodiments, the spacer 340 does not include a first adjustable tab 404 or a second adjustable tab 406. In this embodiment, the spacer 340 may include at least one protrusion along the body 345, thereby allowing the spacer 340 to slide between the frames 207 of the module 102. After the interlocking system 104 is installed, the spacer 340 can be moved between multiple positions by sliding along the frame 207. The protrusion may engage with the frame 207 and be at least partially located within the frame 207 to allow the spacer 340 to move along the frame 207. The position and configuration of the spacer 340 without the first adjustable tab 404 or the second adjustable tab 406 can be... Figure 9B and Figure 10B As seen in the text, and further described in this article.

[0055] In various embodiments, system 100 does not include spacer 340. In this embodiment, second mark 322, third mark 324, and fourth mark 326 can be used to separate modules 102. For example, a technician can align the frame 207 of the first module 102 with the second mark 322, align the frame 207 of the second module 102 with the fourth mark 326, and the space between the first module 102 and the second module 102 can be defined by the distance between the second mark 322 and the fourth mark 326 on the top surface 315.

[0056] The interlocking system 104 may include at least one electrical connector 358, 360 (e.g., conductor, terminal, electrical coupler, etc.). The electrical connectors 358, 360 may be formed of a conductive material, such as a metal like aluminum. The electrical connectors 358, 360 may be electrically coupled to a first module 102 and cause current to flow through the plate 302 and the electrical connectors 358, 360 to a second module 102, facilitating (e.g., forming) an electrical connection between modules 102. The electrical connectors 358, 360 may enable modules 102 to be grounded along rows of modules 102 (e.g., rows 216, 218, or 220).

[0057] The interlocking system 104 may include a first electrical connector 358, which is coupled to the plate 302 and extends at least partially through a first aperture 310. The interlocking system 104 may also include a second electrical connector 360, which is coupled to the plate 302 and extends at least partially through a third aperture 314. The first electrical connector 358 and the second electrical connector 360 may be configured to rotate to facilitate electrical connection between modules 102. Rows of modules 102 (e.g., 216, 218, 220) may be at least partially electrically connected by the first electrical connector 358 and the second electrical connector 360.

[0058] The first electrical connector 358 may include at least one end. The first electrical connector 358 may include a first end 408 and a second end 362. The second end 362 may be opposite to the first end 408. The second end 362 may contact the front surface 330. In various embodiments, the second end 362 may not contact the front surface 330, and the distance between the second end 362 and the front surface 330 may be between 0.3 (e.g., 0.3) and 0.7 (e.g., 0.7) mm. The first end 408 may contact the first module 102, and the second end 362 may contact and / or face the second module 102. During installation, after the first electrical connector 358 is rotated to electrically couple to the first module 102, the second module 102 may be positioned to contact the second end 362. The first electrical connector 358 may rotate while the first end 408 is at least partially located within the frame 207 of the first module 102. The first end 408 may contact the frame 207 and is at least partially inserted into the frame 207.

[0059] The second electrical connector 360 may include at least one end. The first electrical connector 358 may include a first end 410 and a second end 364. The second end 364 may be opposite to the first end 410. The second end 364 may contact the front surface 330. In various embodiments, the second end 364 does not contact the front surface 330, and the distance between the second end 364 and the front surface 330 is between 0.3 and 0.7 mm and includes the end value. The first end 410 may contact the third module 102, and the second end 364 may contact and / or face the fourth module 102. During installation, after the second electrical connector 360 is rotated to be electrically coupled to the third module 102, the fourth module 102 may be positioned to contact the second end 364. The second electrical connector 360 may rotate while the first end 410 is at least partially located in the frame 207 of the third module 102. The first end 410 may contact the frame 207 and is at least partially inserted into the frame 207.

[0060] Once the first end 408 is electrically coupled to the first module 102 and the first end 410 is electrically coupled to the third module 102, the interlocking system 104 can electrically couple the first module 102 and the third module 102. Current can travel from the first module 102 through the board 302 and the second electrical connector 360 to the first electrical connector 358, and then to the third module 102. In various embodiments, the first module 102 is the same as the third module 102, or the second module 102 is the same as the fourth module 102. For example, at least one end of the first electrical connector 358 and the second electrical connector 360 contacts or faces the same module 102.

[0061] Figure 9AFour configurations of the interlocking system 104 are shown. In a first configuration 905, the spacer 340 is removed from the plate 302 after both the first electrical connector 358 and the second electrical connector 360 have contacted and coupled to the base 907 of the array 202. First ends 408 and 410 may contact the base of the array 202. The base 907 may be part of a structure on which the module 102 is mounted. In the first configuration 905, the first electrical connector 358 and the second electrical connector 360 may not rotate, and the first electrical connector 358 and the second electrical connector 360 may be attached to and engaged with the surface 204. For example, the base 907 may have a shape that matches the frame 207, thereby allowing the insertion of the first electrical connector 358 and the second electrical connector 360. The first configuration 905 may correspond to point 212.

[0062] The interlocking system 104 may include a second configuration 909. In the second configuration 909, a spacer 340 may contact a first module 102A and a second module 102B, and first ends 408 and 410 may contact a third module 102C. The spacer 340 may extend in the direction that the second ends 362 and 364 face (e.g., toward the first module 102A and the second module 102B, respectively). The spacer 340 may be in a first position 901, and the spacer 340 being in the first position 901 indicates that the spacer 340 extends between and contacts the modules 102 above the plate 302. The second configuration 909 may correspond to point 208. The first ends 408 and 410 contact the same module 102, and therefore, the interlocking system 104 may not electrically connect the modules 102. In the second configuration 909, the first electrical connector 358 and the second electrical connector 360 may rotate to allow thermal expansion of the third module 102C, as further described herein. The interlocking system 104 can separate the first module 102A and the second module 102B.

[0063] The interlocking system 104 may include a third configuration 911. In the third configuration 911, spacer 340 may contact third module 102C and fourth module 102D. First ends 408 and 410 may contact and couple with the frame 207 of third module 102C and fourth module 102D, and the interlocking system 104 may electrically couple third module 102C and fourth module 102D. Second ends 362 and 364 may face first module 102A and second module 102B, respectively. In the third configuration 911, spacer 340 may extend in the direction facing first ends 408 and 410 (e.g., facing third module 102C and fourth module 102D, respectively). Spacer 340 may be in a second position 903, which may indicate that spacer 340 extends between and contacts modules 102 below plate 302. The third configuration 911 may correspond to point 210.

[0064] The interlocking system 104 may include a fourth configuration 913. In the third configuration 911, the spacer 340 may contact the third module 102C and the fourth module 102D. First ends 408 and 410 may contact and couple with the frame 207 of the third module 102C and the fourth module 102D, and the interlocking system 104 may electrically couple the third module 102C and the fourth module 102D. Second ends 362 and 364 may face the same module 102. In the fourth configuration 913, the spacer 340 may extend in the direction facing the first ends 408 and 410 (e.g., facing the third module 102C and the fourth module 102D, respectively). The spacer 340 may be in a second position 903, which may indicate that the spacer 340 extends between and contacts the modules 102 below the plate 302. The fourth configuration 913 may correspond to point 208.

[0065] To move the spacer 340 between positions 901 and 903 and between configurations 905, 909, 911, and 913, the first adjustable tab 404 and the second adjustable tab 406 can be adjusted. For example, to move the interlocking system 104 from the third configuration 911 to a configuration where the spacer 340 is removed, the first adjustable tab 404 and the second adjustable tab 406 can be pushed toward each other, and the spacer 340 can be moved and removed from the interlocking system 104 in the direction faced by the second end 362 and the second end 364.

[0066] In order to electrically couple the first electrical connector 358 and the second electrical connector 360 to the module 102, the first end 408 and the first end 410 can be configured to rotate within the frame 207. Figures 3 to 4The interlocking system 104 is depicted in a state where the first electrical connector 358 and the second electrical connector 360 have not yet rotated (e.g., not rotated, initial state, etc.), and Figures 5 to 6 The interlocking system 104 is depicted in a state where the first electrical connector 358 and the second electrical connector 360 have been rotated. In various embodiments, the interlocking system 104 may not be electrically coupled to the module 102 until at least one of the first electrical connector 358 and the second electrical connector 360 is rotated to secure the electrical connection between the interlocking system 104 and the two modules 102. For example, Figure 10A An interlocking system 104 is depicted in which a first electrical connector 358 rotates and is electrically coupled to module 102. In a first state, the interlocking system 104 can be inserted into (e.g., mate with) frame 207, and in a second state, the interlocking system 104 can, for example, be electrically coupled to module 102.

[0067] The first end portion 408 may include at least one edge. The first end portion 408 may include a first edge 412 and a second edge 414 continuously formed therefrom. Figures 3 to 4 In the indicated state, the first edge 412 can be aligned and parallel to the second axis A2 extending along the rear surface 402. The top surface 333 of the first protrusion 332 can be positioned along the second axis A2. In various embodiments, the first edge 412 is parallel to the second axis A2 within 1 to 5 degrees (inclusive). The first edge 412 can be straight, and at least a portion of the second edge 414 can be rounded.

[0068] The first end portion 410 may include at least one edge. The first end portion 410 may include a first edge 416 and a second edge 418 continuously formed with the first edge 416. Figures 3 to 4 In the illustrated configuration, the first edge 416 can be aligned with and parallel to the second axis A2 extending along the rear surface 402. In various embodiments, the first edge 416 is parallel to the second axis A2 within a range of 1 to 5 degrees (inclusive). The first edge 416 can be straight, and at least a portion of the second edge 418 can be rounded.

[0069] The first end 408 of the first electrical connector 358 may include at least one corner 420 (e.g., a portion, stop, block, etc.). The corner 420 may have an angle between 85 (e.g., eighty-five) and 95 (e.g., ninety-five) degrees, including the end value. At least a portion of the corner 420 may be rounded. The corner 420 may be coupled to at least one of the first edge 412 and the second edge 414. In various embodiments, the corner 420 is integrally formed with and continuous with the first edge 412 and the second edge 414. For example, the first edge 412 and the second edge 414 include the corner 420.

[0070] The first end 410 of the second electrical connector 360 may include at least one corner 422. The corner 422 may have an angle between 85 and 95 degrees, including the end value. At least a portion of the corner 422 may be rounded. The corner 422 may be coupled to at least one of the first edge 416 and the second edge 418. In various embodiments, the corner 422 is integrally formed and continuous with the first edge 416 and the second edge 418. For example, the first edge 416 and the second edge 418 include the corner 422.

[0071] The first electrical connector 358 and the second electrical connector 360 can rotate clockwise such that corners 420 and 422 can contact (e.g., engage) the frame 207. Corner 420 can limit the rotation of the first electrical connector 358 to no more than 88 (e.g., eighty-eight) to 92 degrees (e.g., ninety-two), including the end value. Corner 422 can limit the rotation of the second electrical connector 360 to no more than 88 to 92 degrees, including the end value. For example, once corners 420 and 422 contact the frame 207, the first electrical connector 358 and the second electrical connector 360 do not need to rotate further. When the first electrical connector 358 and the second electrical connector 360 rotate, corners 420 and 422 can extend beyond the second axis A2. Rotation of the first electrical connector 358 and the second electrical connector 360 beyond 88 to 92 degrees may result in misalignment and increase the difficulty of installing another module 102 into the system 100. In addition, excessive rotation of the first electrical connector 358 and the second electrical connector 360 may increase the torque applied to the frame 207 by the interlocking system 104, thereby increasing the stress and strain on the first electrical connector 358, the second electrical connector 360 and the plate 302, which in turn shortens the service life of the interlocking system 104 and increases the risk of failure.

[0072] Corner 420 may be a first corner 420, and the first electrical connector 358 may include a second corner 424. The second corner 424 may be located at a point on the first end 408 opposite to the first corner 420. When the first electrical connector 358 rotates, the second corner 424 may contact a portion of the frame 207 that differs from the first corner 420, and may limit the rotation of the first electrical connector 358 to no more than 88 to 92 degrees, including the end value. The shape of the second corner 424 may be the same as that of corner 420.

[0073] Corner 422 may be a first corner 422, and the second electrical connector 360 may include a second corner 426. The second corner 426 may be located at a point on the first end 410 opposite to the first corner 422. When the second electrical connector 360 rotates, the second corner 426 may contact a portion of the frame 207 that differs from the first corner 422, and may limit the rotation of the second electrical connector 360 to no more than 88 to 92 degrees, including the end value. The shape of the second corner 426 may be the same as that of corner 422.

[0074] The first electrical connector 358 may include at least one protrusion 602 (e.g., a raised surface, ridge, rib, etc.). The second electrical connector 360 may include at least one protrusion 604. When the first electrical connector 358 and the second electrical connector 360 rotate, the protrusions 602, 604 may be recessed (e.g., engraved, chiseled, recessed, etc.) into the plate 302 to further secure the electrical connection between the interlocking system 104 and the module 102, thereby grounding the module 102. In various embodiments, the protrusions 602, 604 are inserted into the plate 302. For example, each of the first hole 310 and the third hole 314 may respectively include receiving spaces for receiving the protrusions 602, 604.

[0075] The first electrical connector 358 and the second electrical connector 360 may include at least one location. The first electrical connector 358 and the second electrical connector 360 may include... Figures 3 to 4 The first position, the second position, and the... Figures 5 to 6 The third position is shown. The first position can correspond to the unrotated state, the second position can correspond to the partially rotated state, and the third position can correspond to the rotated state of the first electrical connector 358 and the second electrical connector 360.

[0076] Before installation, the first electrical connector 358 and the second electrical connector 360 can be in a first position. In the first position, the interlocking system 104 can be attached to the frame 207. The first protrusion 332, the second protrusion 334, the third protrusion 338, the first electrical connector 358, and the second electrical connector 360 can slide in, insert, or otherwise attach to and contact the frame 207. In the first position, the first edge 412 and the first edge 416 can be parallel to the second axis A2 within 0 (e.g., zero) to 5 degrees (inclusive). After attaching the interlocking system 104 to the frame 207, the first electrical connector 358 and the second electrical connector 360 can be rotated to a second or third position.

[0077] With the first electrical connector 358 and the second electrical connector 360 in contact with the substrate 907 of the same module 102 or array 202 (such as configuration 905 or 909), the first electrical connector 358 and the second electrical connector 360 can be in a second position. In the second position, the first electrical connector 358 and the second electrical connector 360 can be configured to rotate to allow thermal expansion between modules 102. In the second position, the first electrical connector 358 and the second electrical connector 360 may not be electrically connected to the modules, but rather provide space (e.g., tolerances) for movement and thermal expansion of the module 102. For example, the frame 207 may comprise aluminum, which can expand at a rate of about 23 to 24 μm / s / °C. The contact between the frame 207 and the first ends 408 and 410 can change with the thermal expansion and contraction of the module 102. Rotating the first electrical connector 358 and the second electrical connector 360 to the second position allows the module 102 to move within tolerances, which may be defined by the positions of corners 420 and 422 at the second position. The first electrical connector 358 and the second electrical connector 360, in the second position, can hook (e.g., attach) the interlocking system 104 to the frame 207, while allowing space for the expansion of the module 102. In the second position, the first edge 412 and the first edge 416 can extend along an axis angled to the second axis A2, such that the first corner 420 and the first corner 422 extend beyond the second axis A2.

[0078] With the first electrical connector 358 and the second electrical connector 360 in contact with both modules 102 (such as configurations 911 and 913), the first electrical connector 358 and the second electrical connector 360 can be in a third position. The interlocking system 104 can electrically connect the two modules 102 in response to at least one of the first electrical connector 358 and the second electrical connector 360 being in the third position. In the third position, corners 420 and 422 can engage with the frame 207 of the two modules 102 to secure and complete the electrical connection from the first module 102 to the second module 102 via the interlocking system 104. In the third position, protrusions 602, 604 can be at least partially located in the plate 302 to ensure electrical connection and facilitate grounding of the module 102. For example, when the first electrical connector 358 and the second electrical connector 360 rotate, the protrusions 602, 604 can begin to chisel into the plate 302. Protrusions 602 and 604 may begin to be inserted into plate 302 between a second position and a third position of the first electrical connector 358 and the second electrical connector 360. In the third position, first edges 412 and 416 may extend along an axis perpendicular to the second axis A2, and first corners 420 and 422 may extend beyond the second axis A2. In various embodiments, in the third position, first edges 412 and 416 extend along an axis intersecting the second axis A2 at an angle between 88 and 92 degrees, including the endpoints.

[0079] To move the first electrical connector 358 and the second electrical connector 360, the first electrical connector 358 and the second electrical connector 360 can be configured to rotate clockwise from a first position to a second position and a third position. In various embodiments, the first electrical connector 358 and the second electrical connector 360 can be rotated counterclockwise from the first position to the third position. The first electrical connector 358 and the second electrical connector 360 can be rotated using a tool such as a screwdriver, and thus can be rotated without specific tools, thereby simplifying the installation process. The first electrical connector 358 may include an opening 366 for receiving a tool and rotating the first electrical connector 358. The second electrical connector 360 may include an opening 368 for receiving a tool and rotating the second electrical connector 360.

[0080] The second end 362 of the first electrical connector 358 and the second end 364 of the second electrical connector 360 may include at least one indicator (e.g., a mark). The second end 362 of the first electrical connector 358 may include a first indicator 370, a second indicator 372, and a third indicator 374. The second end 364 of the second electrical connector 360 may include a first indicator 376, a second indicator 378, and a third indicator 380. The first indicator 370 and the first indicator 376 may correspond to a first position of the first electrical connector 358 and the second electrical connector 360, the second indicator 372 and the second indicator 378 may correspond to a second position, and the third indicator 374 and the third indicator 380 may correspond to a third position.

[0081] The first indicator 370 may extend along the third axis A3 (e.g., the axis of the first indicator). The third indicator 374 may be centered on and extend along the fourth axis A4 (e.g., the axis of the third indicator). The third axis A3 and the fourth axis A4 may intersect at an angle between 88 and 92 degrees, including the extreme values. The first indicator 376 may extend along the fifth axis A5 (e.g., the axis of the first indicator). The third indicator 380 may be centered on and extend along the sixth axis A6 (e.g., the axis of the third indicator). The fifth axis A5 and the sixth axis A6 may intersect at an angle between 88 and 92 degrees, including the extreme values. The second indicator 372 may be centered on and extend along the seventh axis A7. The seventh axis A7 may intersect the third axis A3 at an angle between 5 and 20 degrees, including the extreme values. The second indicator 378 may be centered on and extend along the eighth axis A8. The eighth axis A8 may intersect the fifth axis A5 at an angle between 5 and 20 degrees, including the extreme values.

[0082] First indicators 370 and 376 can be downward-pointing lines from the middle of the second end 362 and the second end 364, respectively. For example, first indicator 370 can intersect opening 366, and first indicator 376 can intersect opening 368. First indicators 370 and 376 can be etched lines on the second end 362 and the second end 364, respectively. Second indicators 372 and 378 can be recesses (e.g., pits) on the second end 362 and the second end 364, respectively. For example, second end 362 includes an edge 382 (e.g., rim, periphery, etc.), and second end 364 includes an edge 384. First indicator 370 extends from a point on edge 382 to another point opposite to that point on edge 382. First indicator 376 extends from a point on edge 384 to another point opposite to that point on edge 384. Second indicator 372 can be a recess on edge 382, ​​and second indicator 378 can be a recess on edge 384. The second indicator 372 and the second indicator 378 may be indentations with an upward concave shape.

[0083] The second end 362 may include a surface 386 continuous with edge 382. Edge 382 may extend around surface 386. Surface 386 may contact and face module 102. The second end 364 may include a surface 388 continuous with edge 384. Edge 384 may extend around surface 388. Surface 388 may contact and face module 102. A first indicator 370 may be located on surface 386, and a first indicator 376 may be located on surface 388.

[0084] The third indicator 374 may be a recess on surface 386, and the third indicator 380 may be a recess on surface 388. The third indicators 374 and 380 may have shapes such as triangles. The first indicators 370 and 376 may be etched lines extending along the centers of surfaces 386 and 388, respectively. In various embodiments, the shapes of indicators 370, 372, 374, 376, 378, and 380 may be identical. For example, each of indicators 370, 372, 374, 376, 378, and 380 may be a recess on surface 386 or surface 388.

[0085] To determine (e.g., setting, configuring, etc.) the position of the first electrical connector 358 (e.g., first position, second position, third position), one of the first indicator 370, the second indicator 372, and the third indicator 374 can be rotated to align with the first mark 316. For example, to position the first electrical connector 358 in the second position, the second indicator 372 can be rotated to align with the first mark 316, which allows for thermal expansion of the module 102 in contact with the first electrical connector 358. Figures 3 to 4 The image depicts the first indicator 370 aligned with the first mark 316, indicating that the first electrical connector 358 is in a first position. Figures 5 to 6 The third indicator 374 is depicted aligned with the first mark 316, indicating that the first electrical connector 358 is in the third position.

[0086] To determine the position of the second electrical connector 360, one of the first indicator 376, the second indicator 378, and the third indicator 380 can be rotated to align with the fifth mark 328. For example, to position the second electrical connector 360 in a second position, the second indicator 378 can be rotated to align with the fifth mark 328, which allows for thermal expansion of the module 102 in contact with the second end 364. Figures 3 to 4 The image depicts the first indicator 376 aligned with the fifth mark 328, indicating that the second electrical connector 360 is in the first position. Figures 5 to 6 The third indicator 380 is depicted aligned with the fifth mark 328, indicating that the second electrical connector 360 is in the third position.

[0087] In various embodiments, the second indicator 372 and the third indicator 374 are positioned on the surface 386 opposite to the first indicator 370, such that the first electrical connector 358 is rotated counterclockwise to align the second indicator 372 or the third indicator 374 with the first mark 316. In various embodiments, the second indicator 378 and the third indicator 380 are positioned on the surface 388 opposite to the first indicator 376, such that the second electrical connector 360 is rotated counterclockwise to align the second indicator 378 or the third indicator 380 with the fifth mark 328.

[0088] Indicators 370, 372, 374, 376, 378, and 380 facilitate the positioning of electrical connectors 358 and 360. Indicators 370, 372, 374, 376, 378, and 380 mark the rotational positions of electrical connectors 358 and 360 and simplify the installation process. For example, a technician can rotate electrical connectors 358 and 360 by hand or with a tool to align the second indicator 372 with the first mark 316 and the second indicator 378 with the fifth mark 328, thereby setting the interlocking system 104 to isolate module 102 while allowing module 102 to thermally expand.

[0089] In various embodiments, the second end portion 362 may include a second recess 390, and the second end portion 364 may include a second recess 392. The second recess 390 may be located on the side of the first indicator 370 opposite to the third indicator 374. The second recess 392 may be located on the side of the first indicator 376 opposite to the third indicator 380.

[0090] In various embodiments, spacer 340 does not include a first adjustable tab 404 or a second adjustable tab 406. In such embodiments, spacer 450 may include, for example, Figure 9B The interlocking system 104 is shown in three configurations. In the first configuration 908, the spacer 340 contacts four modules 102 and is in a first position 902, the first end 408 contacts the first module 102A, and the second end 362 can face or contact the second module 102B. In the first configuration 908, the first end 410 of the second electrical connector 360 contacts the third module 102C, and the second end 364 can face or contact the fourth module 102D. The first configuration 908 can correspond to, for example... Figure 2 Point 210 is shown. For example, the interlocking system 104 can be in the first configuration 908 at point 210. The interlocking system 104 in the first configuration 908 can be electrically coupled to the third module 102C and the first module 102A, and separate the first module 102A, the second module 102B, the third module 102C and the fourth module 102D. Figure 10B An interlocking system 104 with spacer 340 but without a first adjustable tab 404 and a second adjustable tab 406 is depicted in a first position 902 and a first configuration 908. Figure 10B In the middle, the first electrical connector 358 and the second electrical connector 360 are in the third position.

[0091] The interlocking system 104 may include a second configuration 910. In the second configuration 910, the first end 408 and the first end 410 are in contact with the same module 102. In this case, the spacer 340 is in the second position 904, and the interlocking system 104 may not be electrically connected to the module 102. The interlocking system 104 in the second configuration 910 can separate three of the modules 102. The interlocking system 104 may be in the second configuration 910 at point 214.

[0092] The interlocking system 104 may include a third configuration 912. In the third configuration 912, first ends 408 and 410 may contact different modules 102, while second ends 362 and 364 contact the same module 102. The interlocking system 104 may be electrically coupled to the module 102 contacting the first ends 408 and 410. The interlocking system 104 may be in the third configuration 912 at point 208. The interlocking system 104 in the third configuration 912 may separate three of the modules 102. In the third configuration 912, spacer 340 may be in a third position 906.

[0093] In various implementation methods, such as Figure 9BAs shown, the spacer 340 can have a uniform width along its length. For example, the width of the first end 342 can be the same as the width of the second end 344. In various embodiments, Figure 9B and Figure 10B The spacer 340 cannot be removed from the plate 302.

[0094] Figures 11 to 13 Various examples of the first electrical connector 358 and the second electrical connector 360 are depicted. For example... Figures 11 to 13 As shown, the first electrical connector 358 and the second electrical connector 360 may include at least one protrusion 602, 604. When at least one of the first electrical connector 358 and the second electrical connector 360 rotates within at least one of the first hole 310 and the third hole 314, the protrusions 602, 604 may be inserted into the plate 302. For example, when the first electrical connector 358 and the second electrical connector 360 rotate from a first position to a third position, the protrusions 602, 604 are inserted into the plate 302 to further secure the electrical connection between the module 102 and the interlocking system 104 and to ground the module 102.

[0095] Protrusions 602 and 604 may be closer to the second ends 362 and 364 than the first ends 408 and 410. Protrusions 602 and 604 may be located in at least one of the first hole 310 and the third hole 314, and may be recessed into the plate 302 in the portion defining at least one of the first hole 310 and the third hole 314. Protrusions 602 and 604 may extend around at least a portion of the first electrical connector 358 and the second electrical connector 360.

[0096] In various implementation methods, such as Figure 11 As shown, protrusions 602 and 604 have a width between 1 and 1.4 (e.g., 1.4 mm) and include the end value. In various embodiments, such as Figure 12 As shown, protrusions 602 and 604 have a width between 0.4 (e.g., 0.4) and 0.8 (e.g., 0.8) mm, including the end value. In various embodiments, such as Figure 13 As shown, protrusions 602 and 604 can have a width between 1 and 1.4 mm, including the end value, and can be beveled. In various embodiments, Figure 12 The protrusions 602 and 604 shown can apply a ratio to the plate 302. Figure 11 The protrusions 602 and 604 shown have smaller torque.

[0097] Figure 14A flowchart depicts an example method 1400 for installing system 100. Method 1400 can be performed using various devices or systems described herein, such as system 100. Method 1400 can be performed to install a modular system (e.g., system 100) onto at least one of a roof, rack, mounting base, ground system, and any other structure. Compared to conventional systems and methods, method 1400 can simplify the installation of modular systems and reduce installation time.

[0098] Method 1400 may include mounting (e.g., coupling) a first module to at least one of a rack, frame, mounting base, or other structure to retain the module (1402). The first module may be coupled and secured to the structure via fasteners or clamps. Once the first module is secured, method 1400 may include attaching a second module to an interlocking system (1404). The second module may be coupled and secured to the structure via fasteners or clamps. Once the first and second modules are secured, method 1400 may include attaching (e.g., coupling) an interlocking system between the first and second modules (1406). The interlocking system may be positioned to contact the first and second modules. Specifically, the frames of the first and second modules may engage with the interlocking system. The interlocking system may cooperate with the frames of the first and second modules to attach the interlocking system to the first and second modules. The interlocking system may include spacers, and the spacers may be positioned according to the configuration of the module system. For example, the first and second modules may be contained in a module array, and the spacers may be positioned according to the positions of the first and second modules within the module array. For example, the spacer can be positioned to contact modules other than the first and second modules.

[0099] After the interlocking system contacts the two modules, method 1400 may include rotating the electrical connector of the interlocking system to electrically couple the interlocking system and the two modules together (1408). To continue installing the module array, additional modules can be mounted onto the structure, and when installing module pairs, the interlocking system can be positioned at a point in the module array. For modules above the interlocking system (e.g., in a top view based on the module array), the electrical connector may contact the module but may not provide an electrical connection. In various embodiments, the electrical connector of the interlocking system is rotated to allow for thermal expansion of the modules and may not facilitate an electrical connection between the modules. Thus, the interlocking system can electrically connect and ground rows of modules. The interlocking system may be positioned along the top edge of the rows of modules.

[0100] As used herein, the terms “about,” “approximately,” “substantially,” and similar terms are intended to have a broad meaning consistent with common and accepted usage by one of ordinary skill in the art to which the subject matter of this disclosure pertains. Those skilled in the art, upon reading this disclosure, will understand that these terms are intended to allow for the description of certain features described and claimed, without limiting the scope of these features to the precise numerical ranges provided. Therefore, these terms should be interpreted as indicating that non-substantial or insignificant modifications or alterations to the described and claimed subject matter are considered to be within the scope of this disclosure as set forth in the appended claims.

[0101] It should be noted that the term "example" and its variations, as used herein to describe various embodiments, are intended to indicate that such embodiments are possible examples, representations, or illustrations of possible embodiments (and these terms are not intended to imply that such embodiments are necessarily extraordinary or the best examples).

[0102] As used herein, the term “coupled” and its variations mean that two components are joined to each other, directly or indirectly. This joining can be fixed (e.g., permanent or fixed) or movable (e.g., removable or releasable). This joining can be achieved by directly coupling two components to each other, by coupling two components to each other using a separate intervening component or any additional intermediate component, or by coupling two components to each other using an intervening component integrally formed with one of the two components as a single unit. If “coupled” or its variations are modified by an additional term (e.g., direct coupling), the general definition of “coupled” provided above is modified by the literal meaning of the additional term (e.g., “direct coupling” means that two components are joined without any separate intervening component), resulting in a narrower definition than the general definition of “coupled” provided above. Such coupling can be mechanical, electrical, or fluid coupling.

[0103] As used herein, the term "or" is used in an inclusive (rather than exclusionary) sense, such that when used to connect a list of elements, the term "or" indicates one, some, or all of the elements in the list. Unless otherwise specifically stated, connective language such as the phrase "at least one of X, Y, and Z" should be understood to mean that the elements can be: any one of X, Y, and Z; X and Y; X and Z; Y and Z; or X, Y, and Z (i.e., any combination of X, Y, and Z). Therefore, unless otherwise stated, such connective language is generally not intended to imply that at least one X, at least one Y, and at least one Z are required to be present separately in some embodiments.

[0104] References to the positions of elements herein (e.g., “top,” “bottom,” “upper,” “lower”) are used only to describe the orientation of the various elements in the accompanying drawings. It should be noted that the orientation of the various elements may vary depending on other exemplary embodiments, and these variations are intended to be covered by this disclosure.

[0105] It is important to note that the construction and arrangement of the systems, devices, and methods shown in the various example embodiments are merely illustrative. Furthermore, any element disclosed in one embodiment may be incorporated into or used in any other embodiment disclosed herein. For example, this application… Figures 1 to 14 Any example embodiment described herein can be combined with any other example embodiment described herein. Although only one example of how an element from one embodiment can be incorporated into or used in another embodiment has been described above, it should be understood that other elements from various embodiments can also be incorporated into or used in any other embodiment disclosed herein.

Claims

1. An interlocking system for a photovoltaic module, comprising: A plate, the plate defining a first hole, a second hole and a third hole; A spacer, removably coupled to the plate and extending at least partially through the second hole, the spacer including a first adjustable tab and a second adjustable tab, the spacer being movable through the second hole via the first adjustable tab and the second adjustable tab; A first electrical connector is coupled to the plate and extends at least partially through the first hole, the first electrical connector being configured to rotate to form an electrical connection; as well as A second electrical connector, coupled to the plate and extending at least partially through the third hole, is configured to rotate to form an electrical connection.

2. The interlocking system according to claim 1, wherein, The spacer includes: A first end having a top surface and a bottom surface, the bottom surface being opposite to the top surface; The first adjustable tab extends from the top surface at a first angle between five and twenty-five degrees, including the end value; and The second adjustable tab extends from the bottom surface at a second angle between five and twenty-five degrees, including the end value.

3. The interlocking system according to claim 2, wherein, The spacer includes a second end opposite to the first end, the height and width of the second end being greater than the height and width of the second hole.

4. The interlocking system according to claim 1, wherein, The plate comprises a conductive material.

5. The interlocking system according to claim 1, wherein, The plate has a length between 130 and 150 millimeters (mm) including the end values, and a height between 25 and 45 millimeters including the end values.

6. The interlocking system according to claim 1, wherein, The spacer includes an electrically insulating material.

7. The interlocking system according to claim 1, wherein: The second hole is located between the first hole and the third hole, and the distances from the first hole and the third hole to the second hole are equal. At least one of the first electrical connector and the second electrical connector includes at least one protrusion configured to be inserted into the plate when the first electrical connector and the second electrical connector are rotated.

8. The interlocking system according to claim 1, wherein: At least one of the first electrical connector and the second electrical connector has a first position, a second position, and a third position, wherein the first position corresponds to an unrotated state, the second position corresponds to a partially rotated state, and the third position corresponds to a rotated state, and the first electrical connector and the second electrical connector form an electrical connection at the third position. At least one of the first electrical connector and the second electrical connector includes a first indicator corresponding to the first position, a second indicator corresponding to the second position, and a third indicator corresponding to the third position. The first indicator extends along a first axis, and the third indicator extends along a third axis, which intersects the first axis at an angle between 88 and 92 degrees, including the endpoints.

9. A modular system, comprising: Multiple modules, which are configured to generate electricity; as well as At least one interlocking device, the at least one interlocking device being configured to isolate and electrically connect at least a portion of the plurality of modules, comprising: A plate, the plate defining a first hole, a second hole and a third hole; A spacer coupled to the plate and capable of extending at least partially and moving through the second hole, the spacer contacting at least two of the plurality of modules and configured to separate the at least two of the plurality of modules; A first electrical connector, coupled to the board and extending at least partially through the first aperture, and configured to electrically connect at least said portions of the plurality of modules; and A second electrical connector is coupled to the board and extends at least partially through the second hole, and is configured to electrically connect at least a portion of the plurality of modules.

10. The modular system according to claim 9, wherein: The first electrical connector includes: A first end portion, configured to contact a first module among the plurality of modules; and The second end is configured to face the second module among the plurality of modules; The second electrical connector includes: A first end, configured to contact a third module among the plurality of modules; and The second end is configured to face the fourth module among the plurality of modules.

11. The modular system according to claim 10, wherein, The third module is the same as the first module, or the second module is the same as the fourth module.

12. The modular system according to claim 10, wherein, The first end of the first electrical connector and the first end of the second electrical connector have corners with an angle between 85 and 95 degrees and including the end value, the corners limiting the rotation of the first electrical connector and the second electrical connector to not exceed between 88 and 92 degrees and including the end value.

13. The modular system according to claim 10, wherein: At least one of the first electrical connector and the second electrical connector has a first position, a second position, and a third position, wherein the first position corresponds to an unrotated state, the second position corresponds to a partially rotated state, and the third position corresponds to a rotated state; and The at least one interlocking device electrically connects at least a portion of the plurality of modules in response to at least one of the first electrical connector and the second electrical connector being in the third position.

14. The modular system according to claim 13, wherein: At least one of the second ends of the first electrical connector and the second electrical connector includes a first indicator, a second indicator, and a third indicator, wherein the first indicator corresponds to a first position, the second indicator corresponds to a second position, and the third indicator corresponds to a third position. The first indicator extends along a first axis, and the third indicator extends along a third axis, which intersects the first axis at an angle between 88 and 92 degrees, including the endpoints.

15. The modular system according to claim 9, wherein, The spacer is in a first position, a second position, or removed from the at least one interlocking device, and the spacer is in contact with two of the plurality of modules in the first and second positions.

16. The modular system according to claim 9, wherein, The plate includes a top surface, the top surface including a first mark aligned with the midpoint of the first hole, a second mark aligned with the first edge of the second hole, a third mark aligned with the midpoint of the second hole, a fourth mark aligned with the second end of the second hole, and a fifth mark aligned with the midpoint of the third hole.

17. The modular system according to claim 16, wherein, The plate includes a rear surface that is continuous with the top surface, the rear surface including at least one protrusion configured to facilitate alignment of the at least one interlocking device with at least one of the plurality of modules.

18. An interlocking device, comprising: A plate defining a first opening, a second opening, and a third opening, wherein the second opening is located between the first opening and the third opening; as well as A spacer, coupled to the plate and capable of extending at least partially and moving through the second opening, the spacer comprising: First surface; The first branch extending from the first surface; Second surface; and The second branch extends from the second surface; The first fork and the second fork have a first state and a second state. The first fork and the second fork are closer to each other in the second state than in the first state. When the first fork and the second fork are in the second state, the spacer can move through the second opening.

19. The interlocking device according to claim 18, wherein, The spacer includes an electrically insulating material, and the first and second branches are configured to be pushed together to adjust from the first state to the second state.

20. The interlocking device according to claim 18, further comprising: At least one electrical connector, which is coupled to the board and extends at least partially through at least one of the first opening and the third opening, and is configured to rotate to form an electrical connection.

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