HK1197612B - Pivot-fit frame, system and method for photovoltaic modules - Google Patents

Abstract

A system and apparatus are disclosed including PV modules having a frame allowing quick and easy assembling of the PV modules into a PV array in a sturdy and durable manner. In examples of the present technology, the PV modules may have a grooved frame where the groove is provided at an angle with respect to a planar surface of the modules. Various couplings may engage within the groove to assemble the PV modules into the PV array with a pivot-fit connection. Further examples of the present technology operate with PV modules having frames without grooves, or with PV modules where the frame is omitted altogether.

Description

Pivot-fit frames, systems, and methods for photovoltaic modules

Cross-referencing

This application is co-pending application No. 12/830,249, filed on 7/2/2010 (which claims priority from provisional patent application No. 61/270,122 filed on 7/2/2009); provisional patent application No. 61/255,004, filed on 26/10/2009; and provisional patent application No. 61/351,586, filed on 6/4/2010, in continuation-in-part. This application also claims priority from us 13/351,397, filed on date 1 and 17, 2012, which is a continuation-in-use application no 12/594,935 (filed on date 2 and 7, 2012, and filed on date 2 and 7, and having patent No. 8,109,048), filed on date 10 and 6, 2009. This application also claims the benefit of U.S. provisional patent application No. 61/445,042, filed on day 22/2/2011. The foregoing application is incorporated by reference in its entirety as if fully set forth herein.

Background

Photovoltaic (PV) arrays are formed by mechanically coupling PV modules together to form an array. Most PV module coupling systems require the use of multiple small fasteners that are time consuming. High part count and slow installation times are major obstacles to reducing the cost and adoption of PV systems. Some attempts have been made to reduce the use of fasteners by developing press-fit and hook-type connections. However, these systems suffer from a number of disadvantages.

First, any of these approaches may adequately account for dimensional variations of PV modules and couplings due to manufacturing tolerances. PV modules typically vary by approximately ± 0.10 "along the length and/or width dimensions. When multiple modules form a column in the north-south direction of the PV array, it is critical that any dimensional variation of one module in a column not be passed forward to the next module in the column, as dimensional variations will accumulate in the length of the column and cause significant dimensional differences from one column to the next. Likewise, the same problem exists with the east-west rows of PV modules. This problem, often referred to as marginal occupancy, is solved in track-based systems by the following steps: the modules in the column are more or less spaced from each other on top of the mounting rail so that the next module in the column is properly positioned and/or coupled to the rail only by coupling the module along one axis (east-west or north-south). However, in a trackless system, PV modules are structurally connected to the next module in the north-south and east-west directions. Thus, if the seams between adjacent east-west modules are misaligned due to mixed north-south dimensional variations, it is not possible to complete the mounting of the array. In other systems, mixed east-west variations may cause problems along the north-south axis. Press-fit and hook-type connections do not adequately address or solve tolerance variations.

Second, press-fit and hook connections do not provide a reliable electrical ground engagement between adjacent PV modules. The hook connection itself is a loose fit and therefore cannot provide a constant low resistance ground engagement that will withstand weather conditions over time. Similarly, press-fit connections do not provide a reliable ground engagement unless the material is sufficiently deformed in the connection. In practice, standard PV module frame materials (such as aluminum) require excessive force to achieve such deformation, thereby eliminating any time and cost savings that may occur as heavy tools would be required to transmit the force required for deformation.

Third, press-fit and hook systems fail to reliably provide a secure and durable connection between mating male and female parts. To facilitate a quick and simple connection, the female receiving portion in the connection is made wider than the male connecting portion. This results in a loose or unstable connection that tends to loosen over time as the PV module is subjected to mechanical stress due to wind and snow loading.

Furthermore, it is important that PV installation systems require a design that operates in conjunction with a wide tolerance band. The reason is that tight tolerance PV modules and couplings are very expensive to manufacture. To speed up the use of solar energy, it is necessary to reduce the cost of the solar array, so increasing the cost of tight tolerance parts is not a viable option in the market.

The foregoing examples of related art and limitations related thereto are intended to be illustrative and not exhaustive. Other limitations of the related art will become apparent to those of skill in the art upon a reading of the specification and a study of the drawings.

Summary of The Invention

A system and method for quickly and easily assembling PV modules into a PV array in a robust and durable manner is disclosed herein. In some embodiments, the PV module can have a bezel, with the grooves recessed into the frame at an angle relative to the planar surface of the module. The individual assemblies may be engaged within the angled recesses to assemble the PV modules into a PV array using what may be referred to as a pivot fit connection between the assemblies and the angled recesses. One type of component is a leveling foot, which in some embodiments includes a foot mounted to a support surface and a coupling affixed to the foot. The coupling of the leveling foot may have a male component such as a tongue for coupling within a groove. To mount the PV module to the leveling foot, the module is placed on the tongue and rotated downward until the angle of the groove is substantially aligned with the axis of the tongue. The groove may then be at least partially disposed over the tongue. To complete the pivot-fit connection, the PV modules are simply pivoted down into their PV array in a final angular orientation. This eventually causes the bearing portion in the groove to support the tongue to limit the PV module from moving up or down. The couplings may still allow the position of the PV module in the plane of the PV array to be adjusted to account for tolerance variations.

Another type of coupling is an interlock having an interlock plate and a pair of coupling members, each having a key supported on a shaft. The interlock may be affixed to a groove of a pair of adjacent modules, wherein the angle of the key to the shaft substantially matches the angle of the groove. Rotation of the key and shaft then pivots the interlock into the groove of the adjacent PV module, thereby affixing the adjacent modules together. This final rotation causes the bearing portions in the grooves to support the interlock plate against upward or downward movement of the coupled PV module. The couplings may still allow the position of the PV module in the plane of the PV array to be adjusted to account for tolerance variations.

Other embodiments of the present technology may operate in conjunction with PV modules having frames without angled grooves. For such embodiments, wrap-around brackets are used that engage the upper and lower surfaces of the module frame or, in some embodiments, the PV module laminate itself omitting the frame. In such embodiments, the wraparound assembly may have frame-joint or laminate-joint couplings disposed at an angle in the angled grooves of the embodiments described above. The PV module can initially engage the wraparound assembly substantially at the angle of the coupling and then be pivoted downward to its final position relative to the coupling. This final rotation causes the bearing portions in the wraparound couplings to support the PV module frame to restrain the PV modules in place in the array, as in the trough rack embodiment.

Embodiments of the present technology relate to a photovoltaic module adapted to be connected to an adjacent photovoltaic module by a coupling. The photovoltaic module includes: a photovoltaic laminate; and a frame adapted to provide support for the laminate and including a connection portion adapted to receive the coupling at an insertion angle greater than 2 degrees relative to a plane of the photovoltaic module.

Other embodiments relate to a frame for a photovoltaic module frame adapted to be connected to an adjacent photovoltaic module by a coupling. The frame includes a connection portion including an upper bearing portion adapted to transfer a portion of a downward force on the photovoltaic module to at least a portion of the coupling; wherein the connecting portion is adapted to pivotally receive at least a portion of the coupling.

Another embodiment relates to a photovoltaic module having a frame adapted to be connected to an adjacent photovoltaic module by a coupling and to define a reference plane when connected to the adjacent photovoltaic module. The module includes a first bearing portion; and a second bearing portion; wherein the module is adapted to pivotally engage with the coupling at a position along a length of the frame, the length being substantially parallel to the reference plane, the second bearing portion being offset from the first bearing portion in a direction substantially parallel to the reference plane and perpendicular to the length, the first and second bearing portions being adapted to allow variable positioning of the photovoltaic module relative to the adjacent photovoltaic module in a direction substantially parallel to the reference plane and perpendicular to the length.

Other embodiments relate to a frame for a photovoltaic module adapted to be connected to an adjacent photovoltaic module by a coupling. The frame includes: a connecting portion; a first bearing portion; and a second bearing portion; wherein the first bearing portion and the second bearing portion are located at least partially within the connecting portion, the frame being adapted to pivotally engage with the coupling.

In addition to the foregoing exemplary aspects and embodiments, further aspects and embodiments will become apparent by reference to the figures and by study of the following detailed description.

Brief Description of Drawings

Illustrative embodiments are shown in the referenced figures, which are intended to be regarded as illustrative rather than restrictive.

Fig. 1 is a perspective view of a PV array mounted on a roof.

Fig. 2 is a perspective view of a PV module used in the PV array of fig. 1.

Fig. 3 is a cross-sectional view of the through-thread 3-3 of fig. 2.

Fig. 4 is a cross-sectional view showing a groove in the frame of a PV module.

Fig. 4A illustrates a geometry defined by the sloped surfaces of a groove formed in the frame of a PV module in accordance with embodiments of the present technology.

FIG. 5 is a cross-sectional view of a frame illustrating a groove configuration in accordance with an alternative embodiment of the present technique.

FIG. 6 is a cross-sectional view of a frame illustrating a groove configuration according to other alternative embodiments of the present technique.

Fig. 6A and 6B are front and cross-sectional views of a frame illustrating bearing surface configurations in accordance with other alternative embodiments of the present technique.

Fig. 7 shows the PV array of fig. 1 during fabrication.

Fig. 8 is a first perspective view of a leveling foot in accordance with embodiments of the present technique.

Fig. 9 is a second perspective view of a leveling foot in accordance with embodiments of the present technique.

Fig. 10 is a side view of a leveling foot in accordance with embodiments of the present technique.

Fig. 10A and 10B are perspective views of a leveling foot in accordance with an alternative embodiment of the present technique.

Fig. 11 is a side view of a PV module and mounting feet mounted to a support surface in accordance with embodiments of the present technique.

Fig. 12 is an enlarged side view illustrating a PV module frame groove sliding on a leveling foot tongue at an insertion angle in accordance with embodiments of the present technology.

Fig. 13 is an enlarged side view showing the final coupling of the PV module frame groove to the leveling foot tongue, in accordance with embodiments of the present technique.

Fig. 13A is an enlarged side view of the bearing portion showing the support connection assembly.

FIG. 14 is a perspective view of the array on a support surface as shown in FIG. 1 during fabrication.

Fig. 15 is an exploded perspective view of a first side of an interlock in accordance with embodiments of the present technique.

Figure 16 is a perspective view of an interlocking coupling according to embodiments of the present technology.

FIG. 17 is a perspective view of first sides of interlocks assembled together in accordance with embodiments of the present technique.

Fig. 18 is a perspective view of a second side of an interlock in accordance with embodiments of the present technique.

FIG. 19 is a cross-sectional side view showing the interlock of the key in a first position.

Fig. 20 is a cross-sectional side view showing the interlock of the key rotated 90 deg. from that shown in fig. 19.

Fig. 21 is a cross-sectional side view of a PV module receiving an interlock in accordance with embodiments of the present technique.

FIG. 22 is an enlarged cross-sectional side view of the coupling illustrating the partial rotation interlock shown in FIG. 21.

Fig. 23 is an enlarged cross-sectional side view showing an embodiment in accordance with the present technique fully rotated and locked in place within a module frame groove.

FIG. 24 is a perspective view of a leveling foot supporting a pair of panels and panels joined together by interlocking, in accordance with embodiments of the present technique.

Fig. 24A is a plan view showing four PV modules attached by interlocking, with at least some of the PV modules misaligned.

Fig. 25 is a perspective view of a combined leveling foot and interlocking coupling in accordance with embodiments of the present technique.

Fig. 26 is a perspective view of a ground coupling for grounding a PV array in accordance with embodiments of the present technique.

Fig. 27 is a perspective view of an accessory coupling for affixing an additional component to a PV array in accordance with embodiments of the present technique.

Figure 28 is a perspective view of the coupling of figure 27 to a PV array in accordance with embodiments of the present technique.

Fig. 29 is a perspective view of a leveling foot for receiving a frame of a PV module that does not include a recess, in accordance with embodiments of the present technique.

Fig. 30 is a cross-sectional side view of the leveling foot of fig. 29.

Fig. 30A is a perspective view of a leveling foot for receiving a frame of a PV module that does not include a recess, in accordance with other embodiments of the present technique.

Figure 31 is an alternative embodiment of an interlock for PV modules mounted in a frame without a groove in accordance with embodiments of the present technique.

Fig. 32 is a cross-sectional side view of the interlock of fig. 31.

Fig. 32A and 32B are other alternative embodiments of interlocks for PV modules mounted in a frame without a groove in accordance with embodiments of the present technique.

Fig. 32C is a leveling foot formed with the alternative embodiment shown in fig. 32A and 32B in accordance with embodiments of the present technique.

Fig. 32D is an interlock for PV modules mounted in a frame without a groove according to an alternative embodiment of the present technique.

Figure 33 is a perspective view of at least a portion of a PV array formed with the coupling of figures 29-32.

Figure 34 is a cross-sectional side view of other embodiments of interlocking couplings for coupling PV laminates together that do not include a frame.

Figure 35 is a cross-sectional end view of a track for supporting the interlocking coupling of figure 34.

Figure 36 is a plan view of at least a portion of an array formed with the interlocking couplings of figure 34.

Figure 37 is a perspective view of other embodiments of couplings for operation in conjunction with a bezel PV module on a flat roof in accordance with embodiments of the present technology.

Figure 38 is a cross-sectional side view of the coupling of figure 37.

Figure 39 is a cross-sectional side view of a coupling for operation with a PV module frame having no grooves and adapted to be mounted on a flat roof, in accordance with embodiments of the present technique.

Figure 40 is a plan view of at least a portion of an array formed with the coupling of figure 38 or figure 39.

Figure 41 is a perspective view of other embodiments of couplings for assembling PV modules into an array while the PV modules are tilted about the X-axis and the Y-axis.

Figure 42 is an edge view of a double bond coupling having a pair of opposing keys in accordance with embodiments of the present technique.

Figure 43 is a perspective view of a double bond coupling as shown in figure 42 as may be used in a PV array.

Fig. 44-45 show perspective and front views of a front tilt foot in accordance with embodiments of the present technique.

Fig. 46 illustrates a perspective view of a rear tilt foot in accordance with embodiments of the present technology.

Fig. 47 is a side view of a front angled leg and a rear angled leg supporting a PV module in accordance with embodiments of the present technology.

Fig. 48 is a perspective view of front and rear angled feet supporting PV modules in accordance with embodiments of the present technology.

Figures 49 and 50 are side and perspective views of an intermediate support coupling supporting a PV module, in accordance with embodiments of the present technique.

Fig. 51 and 52 are perspective and side views of a dual tongue leveling foot, in accordance with embodiments of the present technique.

FIG. 52A is a perspective view of a double tongue leveling foot according to an alternative embodiment of the present technology.

Fig. 53 and 54 are perspective views of stamped interlocks with and without an interlock coupling, in accordance with embodiments of the present technique.

Figures 55 and 56 are perspective and side views of a hybrid press-fit coupling in accordance with embodiments of the present technology.

Figures 57 and 58 are front and rear perspective views of a module coupling in accordance with embodiments of the present technique.

Figure 59 is a perspective view of a pair of module accessory couplings attached to PV modules in accordance with embodiments of the present technology.

Fig. 60 and 61 are perspective and front views of a hybrid foot stand supporting PV modules in accordance with embodiments of the present technology.

Figure 62 is a side view of a keyway engagement coupling in accordance with embodiments of the present technique.

Fig. 63 is a perspective view of a coupling foot in accordance with embodiments of the present technique.

Fig. 64 is a perspective close-up view of a portion of a coupling leg, such as that shown in fig. 63, inserted through a plate to illustrate the ability of the rotary coupling.

Figure 65 is a perspective view of a support coupling in accordance with embodiments of the present technique.

Fig. 66 is a perspective view of an interlock such as that shown in fig. 65 attachable to a foot rest.

Fig. 67 is a perspective view of a foot mount such as that shown in fig. 65 that is attachable to a tilt interlock.

Figure 68 is a side view of a support coupling such as that shown in figure 65 installed into a PV module such as that shown in figure 2.

Fig. 68A is a close-up view of fig. 68 at block G.

FIG. 69 is a perspective view of a support rail having a channel. Fig. 70 to 72 are perspective views showing a series of actions for mounting the foot rest in the channel of the rail.

Figure 73 is a perspective view of a squeeze and slide support coupling.

Figure 74 is a perspective view of the slide-in support coupling.

Figure 75 is an exploded perspective view showing how the support coupling and ballast pan (ballast pan) engage the track.

Figure 76 is a perspective view showing how the support coupling and ballast pan engage the track.

FIG. 77 is a side view of the tilt foot engaging the track.

Figure 78 is an end view of the tilt foot as shown in figure 108.

Fig. 79 is a perspective view of the tilt foot as shown in fig. 108 and 109.

Figure 80 is a perspective view of a support coupling in accordance with embodiments of the present technique.

Figure 81 is a perspective view of a support coupling in accordance with embodiments of the present technique.

Figure 82 is a side view of a support coupling in accordance with embodiments of the present technique.

Figure 83 is a side view of a support coupling in accordance with embodiments of the present technique.

Figure 84 is a perspective view of a support coupling in accordance with embodiments of the present technique.

Figure 85 is a perspective view of a support coupling in accordance with embodiments of the present technique.

Figure 86 is a side cross-sectional view of a support coupling in accordance with embodiments of the present technique.

Figure 87 is a side view showing a PV module having a pivot foot proximate to a support coupling mounted to a rail.

Figure 88 is a perspective view of a PV module engaged with a support coupling mounted to a rail at an insertion angle.

Figure 89 is a side view showing rotational movement and various positions of a PV module completing engagement with a support coupling and engaging a pivot foot with another rail.

Figure 89A is an end view of a support coupling similar to the coupling leg shown in figure 63 connected to a track similar to the track shown in figure 69.

Figure 90 is a side view of a PV module mounted to both a support coupling and a pivot foot.

Fig. 91 is a perspective view of two PV modules with the pivot legs inserted between the modules at final tilt angle.

Fig. 92 is an orthogonal close-up view showing the pivot foot interposed between two modules.

Figure 93 is a perspective view of a diffuser support coupling.

Figure 94 is an enlarged side view looking at a portion of the diffuser support coupling along line a-a of figure 93.

Figure 95 is a front view of the diffuser support coupling as viewed along line B-B of figure 94.

Figure 96 is a side view showing engagement of diffuser support couplings coupled to inclined PV modules and also engaged with ballast discs.

Figure 97 is a perspective view of an array of two PV modules mounted to three support couplings, three pivot legs, and three diffuser support couplings each having a ballast pan.

FIG. 98 is a perspective view of a wind diffuser mounted to the array of FIG. 97.

Figure 99 is a perspective view of an array of tilted PV modules mounted to another embodiment of a structural system.

FIG. 100 is a perspective view of the array as shown in FIG. 99 with the wind diffusers attached to the structural system.

Fig. 101-102 are perspective views of a tilted PV module mounted to another embodiment of a structural system.

FIG. 103 is a perspective close-up view of the interlock connected to the structural system at block B as shown in FIG. 101.

Fig. 104 is an additional perspective close-up view of the interlock and structure system at block a as shown in fig. 101.

Fig. 105 is a perspective close-up view of the spring bracket connected to the structural system and PV module at block C as shown in fig. 101.

Fig. 106 is a perspective close-up view of another embodiment of a wind diffuser attached to a PV module with a coupling.

Fig. 107 is a perspective close-up view of a wind diffuser and coupling attached to a PV module of a type similar to the embodiment shown in fig. 106.

Fig. 108 is a perspective close-up exploded view of another embodiment of a wind diffuser illustrating a method of attachment to a PV module without additional coupling assemblies.

Fig. 109 is a perspective view of a wind diffuser of the type shown in fig. 108 attached to a PV module.

Fig. 110 is a perspective view of another embodiment of a wind diffuser and method of attaching to a PV module with a tool-less bracket.

Fig. 111 is a perspective view of a wind diffuser and bracket attached to a PV module, such as shown in fig. 110.

Figure 112 is a perspective view of an array of tilted PV modules supported by another embodiment of the structural system.

FIG. 113 is a side view of the array of FIG. 112.

Fig. 114 is a perspective close-up view of a portion of fig. 112 at block D.

Figure 115 is a perspective view of the structural system and array similar to figure 112 of an array of tilted PV modules supported by another embodiment of the structural system.

Figure 116 is a perspective view of the structural system and array similar to figure 112 of an array of tilted PV modules supported by another embodiment of the structural system.

Fig. 117 is a close-up side view of the support structure of fig. 116 and the connection to the PV module.

Fig. 118 is a perspective view of an array of tilted PV modules supported by another embodiment of the structural system similar to that of fig. 112.

Fig. 118A is a close-up view of a portion of fig. 118 at block E.

FIG. 119 is a cross-sectional side view of the structural system of FIG. 118.

Figure 120 is a perspective view of the structural system and array similar to figure 112 of an array of tilted PV modules supported by another embodiment of the structural system.

Fig. 121 is a cross-sectional side view of the structural system of fig. 120.

Fig. 122 is a close-up view of a portion of fig. 120 at block F.

Fig. 123 is a perspective view of a module clip similar to that shown in fig. 122.

Fig. 124 is a perspective view of a module hook similar to the module hook shown in fig. 122.

Fig. 125 is a cross-sectional side view of a PV module engaging a module hook similar to the module hook shown in fig. 122.

Fig. 126 is a cross-sectional side view of a PV module engaging a module clip similar to the module clip shown in fig. 122.

Fig. 127 is a cross-sectional side view of a PV module connected to the structural system of fig. 122.

Figure 128 is a plan view of an array of tilted PV modules supported by another embodiment of a structural system similar to that of figure 122.

Fig. 129 is a perspective view of another embodiment of a structural system.

Fig. 130 is a perspective view of an array of tilted PV modules supported by the structural system of fig. 129.

Fig. 131 is a cross-sectional side view of fig. 130.

Figure 132 is a perspective view of the pivot-lock support coupling engaged with a track.

Fig. 133 is a side view of fig. 132.

Figure 134 is a perspective view of a portion of an array of tilted PV modules supported by another embodiment of the structural system.

Fig. 135 is a cross-sectional side view of fig. 134.

Fig. 136 is a perspective view of another embodiment of a structural system.

Fig. 137 is a side view of fig. 136.

Fig. 138 is a cross-sectional side view of the structural system of fig. 136 illustrating the operation for engaging PV modules.

Figure 139 is a perspective view of a portion of an array of tilted PV modules supported by another embodiment of a structural system.

Fig. 140 is a cross-sectional side view of fig. 139.

Detailed Description

Referring now to fig. 1, there is shown a perspective view of a PV array 100 comprising a plurality of PV modules 102 arranged on a support structure 103 and in an x-y reference plane. Mounting structure 103 is shown herein as including a flat plane, however it may be a structure having thickness, width, depth, and other dimensions; the height adjustment of the coupling described below is considered relative to any substantial surface or substantial plane, such as a top surface, with reference to any mounting structure, such as mounting structure 103. The y-direction corresponds to the north-south dimension of the array, and the x-direction corresponds to the east-west direction. In the embodiment of fig. 1, the reference plane is defined to be coextensive with a surface of the PV module when the PV module is positioned in its final installed position. However, in other embodiments, some of which are shown below, the reference plane may be above the upper surface of the PV module 102 or below the lower surface of the PV module 102. The PV array 100 can be assembled together and attached to the support structure 103 by leveling feet, wrap around leveling feet, double tongue feet, key coupling feet, brackets, feet, tilt feet or T feet (such as leveling feet 104) and interlocks, wrap around interlocks, series coupled rails, series/parallel couplings, male coupling members, hinges, parallel couplings, double key couplings, or key couplings (such as interlocks 106), the structure and operation of which will be described below. Other components may be coupled to the array 100, such as ground couplings and accessory couplings, for example, as also described below. The PV array 100 of fig. 1 is shown by way of example only. It should be appreciated that the array 100 may have more or fewer modules 102 in the x and/or y directions. In the illustrated embodiment, the support structure 103 may be a roof, such as a pitched roof of a residence or the like. However, it should be understood that the PV array 100 may be supported on a wide variety of other support surfaces, such as, for example, a flat roof, a ground mounted structure, or a vertical support structure (in some embodiments). The defined x-y reference plane of the PV array is substantially parallel to the support structure 103 and may be oriented at any of a variety of angles from horizontal to vertical.

Fig. 2 is a perspective view of a PV module 102 used in the array 100. PV modules without grooves, such as PV module 102, in accordance with the present technique are generally disclosed in U.S. patent No. 7,592,537 entitled "Method and Apparatus for Mounting photovoltaic modules," which is incorporated by reference herein in its entirety. In some embodiments, the module 102 may include a PV laminate 110 surrounded by a frame 112 and supported on two or four sides. The PV laminate 110 can include any of a variety of photovoltaic materials for converting solar radiation into electrical current. The frame 112 may be formed from any of a variety of rigid or semi-rigid materials, including, for example, extruded aluminum with an anodized coating. Other materials, plastics, and coatings are contemplated.

The frame 112 may include a hollow portion for keying the corners and corners together, as is well known in the art, or it may include a screw socket for attaching the corners with screws, as is well known in the art. The frame 112 may include connecting portions (such as grooves 114) according to the present techniques disposed on one, two, three, or all four outer opposing portions of the frame 112 that generally have an outer surface 113. Fig. 3 shows a cross-sectional side view through line 3-3 of fig. 2, showing additional details of the groove 114. In some embodiments, the groove 114 may have the same cross-sectional configuration around the entire perimeter of the frame 112, but in other embodiments, different sides may have different configurations. Fig. 4 is a partial cross-sectional view showing a single side of the frame 112. As seen in fig. 4, the groove 114 may be generally divided into three perpendicular regions (viewed from the perspective of fig. 4). A proximal region 116 adjacent to the outer surface 113 of the frame 112, a distal region 120 defining a back wall of the groove 114 and located furthest from the outer surface 113 of the frame 112, and an intermediate region 118 between the proximal and distal regions.

The proximal end region 116 may be defined by a pair of inclined surfaces (an upper inclined surface 122 and a lower inclined surface 126). The inclined surfaces 122 and 126 may be generally parallel to each other and inclined at a 15 ° angle relative to a planar surface of the module 102 (such as a plane of the surface on which the PV laminate 110 resides). It should be understood that the angled surfaces 122 and 126 need not be parallel to each other, and in other implementations may form other angles of inclination, less than or greater than 15 °, with respect to the flat surface of the module 102. The angle of the angled surfaces 122 and 126 relative to the flat surface of the module 102 defines an angle, referred to herein as an insertion angle, which is described in more detail below. Other examples of insertion angles include, but are not limited to, 2 ° or greater; 5 ° or greater; 10 ° or more and 20 ° or more.

The upper surface 122 includes a bearing portion 124 representing a bottommost portion of the upper surface 122 from the perspective of fig. 4. The bearing portion 124 may be a line along the groove 114 where the inclined surface 122 meets the adjacent inner groove wall. The bearing portion 124 may have a sharp profile, or in other embodiments the bearing portion may instead have a rounded or flat profile. Similarly, the lower inclined surface 126 may include a bearing portion 128 representing an uppermost portion of the lower surface 126 when viewed from the perspective of FIG. 3. The bearing portion 128 may be a line along the groove 114 where the inclined surface 126 meets the adjacent inner wall. The bearing portion 128 may have a sharp profile, or in other embodiments the bearing portion may instead have a rounded or flat profile. The bearing portions 124 and 128 may be offset from each other in the horizontal direction; that is, the bearing portion 128 may be located on the outer surface 113 of the frame 112 and the bearing portion 124 may be located at a distal end of the outer surface 113 in the horizontal direction.

The particular geometry defined by the inclined surfaces 122 and 126 is described in more detail below with respect to fig. 4A. As described above, in some embodiments of the present technology, the inclined surfaces 122 and 126 may be parallel to each other. In such embodiments, the distance m represents the perpendicular distance between the two inclined surfaces 122 and 126. Fig. 4A also shows planes p and q (into the page), which are planes passing through the bearing portions 124 and 128, respectively, and which are substantially parallel to the planar surface of the module 102. The distance n is the perpendicular distance between the planes p and q. In some embodiments, distance m may be greater than distance n. This importance is explained in more detail below. In some embodiments, distance m may be, for example, 0.51 "and distance n may be, for example, 0.50". These dimensions are merely illustrative and may be varied together or not to scale in other embodiments.

The intermediate region 118 includes an upper recess 130a in an upper portion of the groove 114 and a lower recess 130b in a lower portion of the groove 114 (as viewed from the perspective of fig. 4). Together, the recesses 130a and 130b define a keyway 130 in the middle portion of the groove 114 for receiving the keys of various engagement members as described below. The length from the upper recess 130a to the lower recess 130b may be longer than the distance between the inclined surface 122 and the inclined surface 126. The distal region 120 is defined between the distal-most portion of the keyway 130 and the rear wall 132 of the groove 114.

In the above embodiments, the bearing portions 124, 128 are provided in the inclined surfaces 122, 126, respectively. It should be appreciated that in other embodiments the bearing portions 124 and/or 128 may be disposed in other shaped surfaces of the frame 112. To take one such example, FIG. 5 shows the bearing portion 128 in an inclined surface as described above. However, the bearing portion 124 may be a protrusion that protrudes from an otherwise substantially planar surface that is parallel to the planar surface of the module 102. In other embodiments, the bearing portion 128 may be formed as a protrusion on another planar surface in addition to the bearing portion 124 or in place of the bearing portion 124. Other possible configurations of the surfaces comprising the bearing portions 124, 128 will be apparent to those skilled in the art in view of this disclosure and the disclosure below, providing that the bearing portions 124 and 128 are spaced from each other in the vertical direction and offset from each other in the horizontal direction. The distance m of fig. 4A is found in fig. 5 in a manner similar to fig. 4A. As shown in fig. 5, a first plane r may be defined tangent to bearing boss 124 and the proximal (outer) edge of upper angled surface 122. A second plane s may be defined tangent to bearing ledge 128 and the distal (inner) edge of lower inclined surface 126. The distance m may be defined by the perpendicular distance between two defined planes.

In addition to variations in the proximal region 116 as described above, in other embodiments the regions 118 and/or 120 can have other configurations. For example, fig. 6 shows a cross-sectional side view as in fig. 4, but with the keyway 130 omitted. In some embodiments, the frame 112 may have four sides, with a first side having a configuration as shown in fig. 4 and an opposite side having a configuration as shown in fig. 6, or other configurations as will be apparent to those of skill in the art. In other embodiments, the frame 112 may have two sides with the groove 114 and two sides without the groove.

As explained below, the present technique includes couplings having a male component that fits within a female component (such as groove 114) at an insertion angle. In another embodiment, it is contemplated that one or more of the respective positions of the male and/or female components may be reversed such that the frame includes or forms a male component and the coupling includes a female component that receives the male component of the frame at an insertion angle.

Fig. 6A and 6B illustrate other embodiments of the frame 112, where fig. 6A is a front view of the frame 112 and fig. 6B is a cross-sectional view through line a-a of fig. 6A. In this embodiment, the frame 112 does not have the angled groove 114 with bearing surfaces 124, 128 as described above, and the structure of the frame 112 defining the proximal section 116, the intermediate section 118, and the distal section 120 may be omitted. In this embodiment, the bearing surface 128 may be defined by an aperture 127 formed through the front face 113 of the frame 112. The bearing surface 124 may be defined by an aperture 129 formed through the rear face 115 of the frame 112 opposite the front face 113. The holes 127, 129 may be circular with various diameters and formed by drilling through the front and rear faces 113, 115. However, in other embodiments, the holes may be square, rectangular, oval, or other shapes and formed by methods other than drilling. Bearing surface 128 may be located on a bottom portion of bore 127 and bearing surface 124 may be on a top portion of bore 129.

As can be seen in fig. 6A, the apertures 127, 129 are aligned with each other in the horizontal direction from the perspective of fig. 6A, but the aperture 127 defining the bearing surface 128 may be higher in the vertical direction than the aperture 129 defining the bearing surface 124. As explained below, various couplings are provided having a male portion, such as, for example, a tongue 148 as shown in fig. 8-10. These convex portions may be inserted between the bearing portions 128 and 124 shown in fig. 4 at an insertion angle parallel to the upper surface 122 and the lower surface 126 of the frame 112. The male portion or frame 112 may then be rotated such that the male portion engages the bearing portions 128 and 124 to limit relative movement between the male portion and the bearing surfaces in the vertical direction. This feature of the present technique will be described in more detail below.

Referring again to fig. 6A and 6B, the male couplings described below may have a diameter and length to fit within the bores 127 and 129. In the case where the frame 112 is formed with the holes 127 and 129 according to the present embodiment, the male coupling may be inserted through the hole 127, and then through the hole 129. The coupling may be inserted at an insertion angle defined by an axis passing through the holes 127 and 129. Since the holes are offset from each other in the vertical direction, this insertion angle may be greater than 0 °, and may be 15 °, for example. The male portion or frame 112 may then be rotated such that the male portion engages the bearing surfaces 128 and 124 to limit relative movement between the male portion and the bearing surfaces 128, 124 in the vertical direction. This engagement will again be described in more detail below.

Fig. 7 is a perspective view of an array to be formed during manufacture of PV array 100, similar to fig. 1. The present technology relates to a system of connection assemblies for PV arrays located in a reference plane. Generally, a system connects a first connection assembly and a second connection assembly together. As explained below, the first connection assembly and/or the second connection assembly may be any one of a PV laminate, a PV module frame, a coupling member, and a bracket. One of the connecting members includes a first or upper bearing portion and a second or lower bearing portion. These bearing portions may be the bearing portions 124 and 128 described above within the groove 114. As explained below, in other embodiments, the bearing portion may be formed on other connection assemblies.

As also explained below, the bearing portions are offset from each other in a direction substantially parallel to the reference plane. For example, in fig. 4, the reference plane may be defined by the laminate 110 of the module 102. Viewed from the perspective of fig. 4, the bearing portion 124 is at a further end than the bearing portion 128 in a direction substantially parallel to the laminate 110 and a reference plane defined by the laminate 110.

The first component may be engaged with the bearing portions in a manner that allows the first component to be inserted between the bearing portions. Thereafter, the first assembly may be pivoted to a position between the bearing portions, wherein the bearing portions resist relative movement of the connection assembly in a direction substantially perpendicular to the reference plane while allowing relative movement of the connection assembly in a direction substantially parallel to the reference plane. These features are explained below.

Fig. 7 shows a first row of leveling feet 104 attached to the support structure 103. As indicated above, the support structure 103 may be a roof, such as a roof of a residence. Such roofs typically include rafters or joists (105 in fig. 14) located below the roof surface. In some embodiments, the position of the leveling feet 104 along the x-axis may correspond to the position of rafters or joists below such roofs, such that the leveling feet 104 are bolted directly to the rafters or joists to ensure that the array 100 is properly supported. Those skilled in the art will recognize that the leveling feet may be oriented at 90 deg. to the position shown when the rafters extend in the east-west direction. As explained below, couplings according to the present technology may be used for PV arrays on other types of surfaces, in which case bolting the leveling feet 104 to rafters or joists may not be considered. In such embodiments, the leveling feet 104 can be positioned as desired, and can be combined into a unitary coupling, such as at the seams between modules (not labeled), which can be similar to the module 102 shown in fig. 1, and interlocks (not shown), which can be similar to the interlocks 106 shown in fig. 1, as explained below.

Details regarding the construction of an exemplary leveling foot 104 will now be described with reference to fig. 8-10. The present disclosure shows a mechanism for leveling a photovoltaic array. In contrast to the present configuration is the use of a trough. Such slots may reside in the vertical portion of the bracket, which may also include a peg for variably tightening at different locations in the slot, such devices do not take into account the mechanism as it may be a simple fastener and slot. The apparatus shown herein may include a mechanism for leveling. In general, the leveling feet 104 include a base 134, the base 134 may be mounted to a support structure (not shown) that may be similar to the support structure 103 shown in fig. 1 via a peg or other fastener (not shown) that fits through a mounting hole 136 adapted to expose a portion of the support surface. In some embodiments, the base 134 is secured to a separate structural member, rail, attachment device, or snap-on attachment device (such as a snap-on post) rather than being directly attached to the support structure 103. Other threaded bores 137 are provided in the base 134 for receiving first ends of the double threaded studs 140.

The leveling foot 104 also includes a foot coupling 138 for coupling the leveling foot to a PV module, such as the module 102. Coupling 138 is threaded through a hole 136 in foot coupling 138 onto a second end of double threaded stud 140. The threads of coupling aperture 136 may be reversed relative to the threads in aperture 137 in base 134. The double threaded stud 140 includes a tool receiving recess 144 for receiving a tool that may be used to rotate the double threaded stud 140. As stud 140 is rotated in a first direction, foot coupling 138 moves away from base 134 to raise an attached PV module (not shown) away from a support structure (such as support structure 103 shown in fig. 7). Rotation of stud 140 in the opposite direction moves foot coupling 138 and the attached PV module (not shown) closer to the support structure. It may happen that such a support structure may not be flat but may comprise locally or globally large and/or small peaks and valleys which stand out from the highly reflective properties of the laminate. Mounting foot couplings 138 for quick and simple translation allows these peaks and valleys to be corrected and ensures more effective planarity of the finished array (such as array 100 shown in figure 1) in the x-y reference plane.

A height adjustment mechanism, such as a stud 140, allows the height of the leveling foot 104 to be adjusted even after the leveling foot 104 has been connected to the PV module 102. Thus, the height adjustment of the leveling feet 104 may be independent of the operation of engaging the leveling feet 104 with the PV module 102 and/or the support structure 103. This type of configuration (as shown in fig. 8) greatly simplifies the process of leveling a PV array, such as array 100, because the installer can adjust the height of the leveling feet 104 even though the leveling feet 104 are already installed. The skilled person will appreciate that making the height adjustment after the leveling feet 104 have been connected to the modules 102 and attached to the support structure 103 means that the installer can readily understand the planar relationship between adjacent PV modules when making the final height adjustment (since the PV laminate very clearly defines a plane due to its glass surface), thereby substantially speeding up the process of arranging each module 102 in the array 100 into approximately the same plane. Adjusting the height of each leveling foot 104 in the array 100 after at least two PV modules 102 are in place is much easier because the PV modules 102 have a better understanding of the planar relationship between adjacent modules. Further, the recesses 144 may be positioned to allow the studs 140 to rotate from the top even after substantially all of the PV modules 102 in the array 100 have been installed. This configuration provides additional benefits during the process of leveling the PV array 100 due to the ease of understanding the entire plane of the PV array 100 when a large number of modules 102 have been installed; for example, to enable an installer to return to the leveling feet located in the middle of the array and quickly adjust their height to fine tune the planarity of the array 100.

It is contemplated that some or all of the components of leveling foot 104 may be made of corrosion resistant materials or may include a corrosion resistant coating to prevent corrosion from current and/or moisture. Such corrosion protection may help prevent loss of ground continuity over time, as foot couplings 138 may provide ground engaging connections between adjacent PV modules.

Those skilled in the art will appreciate that a wide variety of other height adjustment mechanisms may be used in addition to or in place of the above-described components. Moreover, the base 134 may be modified or replaced depending on the support structure on which the array is mounted. For example, the base 134 may be replaced with a pedestal adapted to attach to a seam or trench of a metal roof or an instant-connect pedestal that incorporates a ceiling lamp into the base 134. In other embodiments, the base 134 may be adapted for pitched roofs of both flat and undulating design. In still other embodiments, the base 134 may be adapted to attach to a structural member (such as a strut, a round or square steel tube, an i-beam, and so forth). Those skilled in the art will appreciate that the base 134 may also be adapted to be suitably disposed on a variety of other support structures or surfaces.

Foot coupling 138 of leveling foot 104 further includes a central portion or flange 146, a tongue 148 extending from one side of flange 146, and a key 150 disposed on an axle 152 extending from an opposite side of flange 146. The PV module can be mounted to the support structure by two leveling feet on opposite sides of the module along the y-axis direction, as generally shown in fig. 1, with a tongue 148 of a first leveling foot fitting on a first side within a groove (such as groove 114 shown in fig. 3, 5, and 6) and a key 150 of a second leveling foot fitting on an opposite side within the groove (such as groove 114). This aspect of the present technique will be explained below with reference to the perspective view of fig. 7 and the side views of fig. 11-13. The first row may mount all keys or one side mounting keys and the other side mounting tongues.

Fig. 10A and 10B illustrate an alternative embodiment of the leveling foot 104. This embodiment may include a base 134 and a foot coupling 138 as described above. However, in this embodiment, the foot coupling 138 may be affixed to the base 134 via a foot stud 143. The foot stud 143 may be mounted to the base 134, for example, via a retaining pin 141. In this embodiment, the top portion of the stud 143 may be threaded and fit within a threaded retainer 142 in a flange 146 of the foot coupling 138. In this embodiment, the height of the foot coupling 138 may be adjusted relative to the base 134 by rotating the coupling 138 on the stud 143 prior to coupling the leveling foot 104 to the module 102.

In some embodiments, the first leveling foot (104 a in fig. 7, 11, 12, and 13) can be mounted to a support surface. On a sloping roof, leveling feet may be mounted on the downhill side of the module 102. The leveling foot 104a may be secured to the support surface 103 such that the tongue 148 of the leveling foot 104a faces the side to which the module 102 is to be attached.

The module 102 may then be in contact with the mounting leveling foot 104a and supported thereon such that portions of the upper angled surface 122 of the groove 114 rest on the tongue 148 of the mounting leveling foot 104 a. Thereafter, the module 102 may be rotated downward in the direction of the arrows shown in fig. 7 and 11. As discussed above, the upper and lower angled surfaces 122, 126 may be disposed at an inset angle (e.g., 15 °) relative to the planar surface of the module 102. Fig. 12 shows the module 102 having been rotated to a point where the angle of the module 102 relative to the x-y reference plane is substantially equal to and opposite the insertion angle of the angled surfaces 122, 126. At this point, the sloped surfaces 122, 126 will be substantially parallel to the upper and lower surfaces of the tongue 148, and the groove 114 may then be slid over the tongue 148 to seat the tongue 148 within the groove 114 and seat the module 102 on the leveling foot 104 a. It should be appreciated that in various embodiments, the groove 114 may slide over the tongue 148 when there is some angular difference between the groove 114 and the tongue 148. Those skilled in the art will recognize that formal variations in the final dimensions of mating parts may lead to the following situations: even though the groove 114 may be slightly narrower than the tongue 148, positioned as shown in fig. 12, the groove 114 may still slide over the tongue 148. The ramp 147 on the tongue 148 may help to start the insertion process and the ground tooth 149 may then cut off its path as it slides into position.

Fig. 13 shows the module 102 when rotated further to the completed position of the module 102, where the flat surface of the module 102 is substantially parallel to the x-y reference plane. In this and other embodiments described herein, the reference plane may be at or above the upper surface of the PV laminate 110 (as shown by dashed line 155a in fig. 13), between the upper and lower surfaces of the PV laminate 110, at the lower surface of the PV laminate 110 (e.g., as shown by dashed line 155b in fig. 13), or below the PV laminate 110 (as shown by dashed line 155c in fig. 13).

The space between the upper and lower inclined surfaces 122, 126 engaged by the tongue is the distance m described above in fig. 4A when the groove 114 slides over the tongue 148 in fig. 12. However, once the module is rotated to the position shown in fig. 13, the separation between the surfaces 122, 126 engaged by the tongues is a small distance n. In some embodiments, the height of the tongue may be slightly less than or equal to the distance m, and slightly greater than or equal to the distance n, taking into account the dimensional variations of the surfaces 122, 126 and the tongue 148. For example, the height of the tongue along the dimension between surfaces 122 and 126 can be 0.010 "(which is less than distance m), and 0.010" (which is greater than distance n). Thus, in an embodiment, the tongue 148 and surfaces 122, 126 of the groove 114 have a cumulative tolerance range of-0.010 "to + 0.010" for mating parts. Those skilled in the art will recognize that the difference between m and n provides a vertical (z-axis) tolerance footprint. In the previous example, even a tongue of.010 "undersized to the insertion angle can result in a tight fit that bends the frame opening (in the direction of arrow 151) and thereby deforms the material 0.010" at the final 0 ° position. The dimensions of the tongue 148 with respect to the distances m, n may differ from these dimensions in various embodiments. For example, the height of the tongue 148 may be greater than both m and n, as long as n is less than m.

The tongue 148 and groove 114 coupling or connection described above helps to point out some of the benefits of a pivot fit connection. Such a configuration allows simple part insertion and solid state connection in the final position without relying on slow complex press fits (which are difficult in view of the materials, tolerances and dimensions of typical PV modules) or mechanical fasteners. Furthermore, the fact that the insertion angle is different from the final angle means that the contact surface area of the material is smaller (compared to the case where the groove 114 has a straight lip), thereby enabling low friction, simple alignment adjustment even at the final 0 ° position. Further, the pivot-fit connection system may also help increase horizontal tolerance occupancy.

Thus, after simply sliding over the tongue 148 at the insertion angle, the module 102 may be rotated to the position shown in fig. 13 to provide a pivot-fit connection of the groove 114 to the tongue 148. The present disclosure may also refer to such connections as follows: the tongue 148 pivotally engages the groove 114 or the groove 114 pivotally receives the tongue 148. In particular, the bearing portion 124 in the upper angled surface 122 supports the tongue 148 and exerts a downward force on the tongue 148 (such as in the z-direction perpendicular to the x-y reference plane). In the position of fig. 13, the bearing portion 128 in the lower inclined surface 126 similarly supports the tongue 148 and exerts an upward force (in the z-direction) on the tongue 148.

The PV module 102 provides a lever arm and the moment allows the PV module to pivot from the position of fig. 12 to the position of fig. 13 about the bearing portion 124, typically under the weight of the module 102. This results in the tongue 148 supporting the bearing portions 124, 128 of the surfaces 122, 126, which via the curved opening of the frame elastically deforms the frame 112 around the tongue 148. Those skilled in the art will recognize that the generally C-shaped connecting portion 114 of the frame 112 may naturally flex the opening when loaded on the bearing portions 124, 128. The tongue support of the surfaces 122, 126 accounts for any variation in the z-axis dimension of the tongue 148 and groove 114. This provides a tight coupling and prevents any relative movement along the z-axis between the leveling foot 104a and the coupled portion of the frame 112. Those skilled in the art will recognize that even if the height of the tongue 148 is greater than m, thereby requiring the tongue 148 to slightly open the groove 114 during insertion at the insertion angle, rotation to the final angle of fig. 13 increases the force between the bearing portions 124, 128 and the tongue 148, thereby creating a final tight fit that is much tighter than when rotated as shown in fig. 12.

While constrained in the z-direction, the coupled frame portion 112 and module 102 are able to move along the surface of the tongue 148 in the direction of arrow 154 of fig. 13. This allows the y-position of the module 102 to be quickly and simply adjusted after the pivot-fit connection is established between the module and the leveling feet 104a, for example to account for any tolerance variations in the y-dimension of the module 102. As explained in the background section, this variable positioning feature prevents or improves dimensional variation that accumulates along the length of the module column in the y-direction. As shown in fig. 8, the tongue may include a guide clip 156 to prevent the groove 114 from disengaging from the tongue 148 while making adjustments in the y-direction. Those skilled in the art will also recognize that the variable locating feature 154 of the pivot-fit connection may cause the pivot point (such as the bearing portion 124 in the above example) to slide slightly as the part is pivoted into position. In some embodiments, the bearing portions 128, 128 include non-concave shapes (such as convex, faceted, ribbed, etc.) to ensure simple horizontal adjustability.

Fig. 13A shows an additional enlarged view of the force exerted downwardly by the bearing portion 124 on the tongue 148 and upwardly by the bearing portion 128 on the tongue 148. In some embodiments, the bearing portion may be formed such that there is an interface region 125 between the bearing portion 124 and the tongue 148, where the two components are laid in contact with each other. The same interface area 125 may exist between the bearing portion 128 and the tongue 148. The size of the interface area may be determined by the shape of the bearing portions 124, 128 and the degree of deformation of the bearing portions 124, 128 and/or tongue 148.

A force F is exerted by the bearing portion 124 downwardly on the tongue 148. These forces are vectors having a direction and magnitude and may be summed together into a resultant force vector FV 1. Similarly, a force F is applied by the bearing portion 128 upwardly against the tongue 148. These forces are vectors having a direction and magnitude and may be summed together into a resultant force vector FV 2. In an embodiment, the above-described coupling between the tongue 148 of the groove 114 and the bearing surfaces 124, 128 may result in equal and opposite force vectors FV1 and FV 2. The contact area 125 and the resultant equal and opposite force vectors FV1 and FV2 may be caused by any of the coupling elements described below of the connecting assembly connected with the bearing portion. In other embodiments, the resultant force vectors FV1 and FV2 at the bearing surface of the coupling need not be equal or opposite.

With the pivot-fit connection described above, the present technology provides an extremely quick and simple way of attaching PV modules to a coupling such as a leveling foot. The modules are engaged in position and fixed relative to z-axis movement while still being adjustable to account for dimensional differences in module size by the simple act of sliding the grooves in the module frame at the insertion angle over the couplings and then bringing the modules downward to their final angular orientation. The tolerance occupancy mechanisms described above also account for dimensional variations in the size of the mating components and slight variations in the length of a row or column of modules due to other factors, such as misalignment of the mating parts and non-uniformity of the mounting structure.

The tongue 148 may include electrical grounding teeth 149 (one of which is shown in fig. 8 and 9) in the form of an inverted v-shaped protrusion extending from an upper surface of the tongue 148 along the y-dimension when oriented as shown in fig. 7. It may alternatively be a v-shaped protrusion extending from the lower surface of the tongue 148 along the y-dimension. Other shapes for the electrically grounded teeth or other configurations are expressly contemplated herein but are generally described below as cutting teeth. When the module 102 is pivoted to its final position such that there is a tight fit of the tongue 148 between the upper surface 122 and the lower surface 126, the grounding teeth may bite through the anodized layer and make electrical contact with the underlying metal to establish electrical grounding contact with the connection portion 114 of the module 102. The keys 150 (see fig. 8, 9, 10, and 11) on opposite sides of the leveling foot 104 may also include one or more cutting teeth for establishing a ground connection to the connecting portion 114 of the module to which it is coupled, as explained below. Thus, when oriented with the tongue facing east-west, the leveling feet may provide a ground engagement between the modules along either the y-dimension or the x-dimension. Those skilled in the art will recognize that the connection portion of the PV module frame 112 may be adapted to create a reliable ground engagement between the frame 112 and the coupling 138. As explained below, a mechanism such as a ground coupling may be used to electrically connect the array 100 to a ground component on the support structure 103 or directly to ground.

The freestanding (not mounted to a support surface) leveling foot 104b may engage the recess 114 on the opposite side of the module 102 before the module 102 is attached to the mounted leveling foot 104a as described above. The free standing leveling foot 104b may be coupled to the opposite side of the module by locking a key 150 of the foot 104b into a keyway 130 in the recess 114. This is done by the following steps: the leveling foot 104b is simply held at an angle of approximately 90 deg. to its final upright position, the key 150 is passed through the opening of the recess 114, and then rotated back 90 deg. to engage the key with the keyway 130a, 130 b. The key 150 may be shaped to allow it to pass through the opening of the groove 114 while remaining at 90 ° from its final upright position, yet engage behind the lip of the groove 114 when rotated to its final upright position. This coupling is similar to the coupling of the interlock 106 to the module 102, as described in more detail below, because the interlock coupling 164 and the foot coupling 138 both include keys 150, 178 (see discussion below).

After the module 102 is coupled to the tongue 148 of the mounted leveling foot 104a and is tolerant of adjusting the y-position of the module, the leveling feet 104b coupled to the opposite side of the module 102 may then be secured to the support structure 103. Once the module is rotated down to its final orientation, the leveling feet 104b now rest on the support structure 103. The base 134 of the leveling foot 104b may simply be rotated about the z-axis until it is aligned with the rafter or joist below the support structure 103, and then bolted down to provide quick, simple and accurate attachment of the leveling foot 104 b. The tongue 148 of the leveling foot 104b is oriented along the y-axis and is ready to accept the next panel in the y-direction. The above process may then be repeated.

Those skilled in the art will recognize that the configuration of mounting PV modules 102 by tongue connections on one side and key connections on the opposite side as shown in fig. 11-14 effectively utilizes the rigidity of support surface 103 to help create a rigid interlocking array 100. For example, if the leveling feet 104 of the array 100 are not attached to the support surface 103, the tongues may simply slide back out of the grooves 114 when lifted to approximately a 15 insertion angle as described above. The present technique significantly reduces the total material required for installation when compared to conventional rail-based systems (which add rails for robustness) or other interlocking systems that incorporate rigid coupling systems. In addition, the pivot-fit action as described in this disclosure provides a quick "drop" method as a PV module that is much faster than prior art systems that rely on press-fit connections and/or conventional fasteners.

In the above embodiment, the key 150 of the free standing leveling foot (104 b) engages the groove 114 and the tongue 148 of the installed leveling foot (104 a) engages the groove 114. It is contemplated that this configuration may be reversed in other embodiments. That is, the key 150 of the installed leveling foot may engage the groove 114 and the tongue 148 of the freestanding leveling foot may engage the groove 114. Also, in either embodiment, the key 150 may be coupled within the groove 114 before the tongue 148 is on the opposite side, or vice versa. In still other embodiments, each of the PV modules 102 of the first row array 100 can be installed by: the key 150 is engaged with the groove 114 on the lower and upper sides in the orientation shown in fig. 14, and then each of these upper and lower leveling feet 104 is subsequently attached to the support surface 103. Subsequent rows may then include the above-described method including tongue engagement on the lower side and key engagement on the upper side.

In some embodiments, the coupling between the connection components (such as the tongue 148 and the bearing portions 124, 128) is achieved without a press fit and without frictional forces that act to hold the respective components together. In many embodiments the securement of the final array is ultimately obtained from the roof or support structure, rather than coupling.

Fig. 14 shows a first row of PV modules 102 assembled together on a support structure 103. As can be seen in fig. 14, in addition to leveling feet 104, the present technique may also employ interlocks 106 for affixing adjacent modules 102 together along the x-axis. The structure of the interlock 106 will now be described with respect to the various views of fig. 15 through 20. The interlock 106 generally includes an interlock plate 162, the interlock plate 162 including a pair of openings 166 that receive a pair of interlock couplings 164, the interlock couplings 164 being retainable in the openings 166 via an interference fit. As seen, for example, in the perspective view of fig. 15, the interlock 106 includes a first surface 168, the first surface 168 having a pair of ribs 170 spanning a substantial portion of the length of the interlock 106. In some embodiments, the ribs 170 may also be shown on the tongue side of the panel, increasing the structural properties of the interlock 106.

The upper surface of the top rib 170 and the lower surface of the bottom rib 170 are spaced from each other so that the ribs fit together properly within the groove 114, as explained below. Instead of a plurality of individual ribs, the element 170 may instead comprise a single rib or protrusion having a top surface that mates with the top surface of the upper rib 170 and a bottom surface that mates with the bottom surface of the lower rib 170. The lower portion of the interlocking plate 162 may include a lip 172, the lip 172 being positioned below the lower surface of the frame 112 of a pair of adjacent modules 102 once the interlock 106 is attached to the PV module 102. The lip 172 may enhance the structural performance of the interlock 106 and may be omitted in other embodiments.

Each interlocking coupling 164 may be identical to one another and may include a nut portion or flange, such as flange 174, a tongue 176 extending from flange 174 in a first direction, and a key 178 attached to a shaft 180 extending from flange 174 in an opposite direction. The tongue 176 may be shaped as other tongues described in this disclosure (such as the tongue of fig. 8). The structure and operation of the key 178 will now be described. It should be noted that the key 150 on the leveling foot 104 (referenced above with respect to leveling foot 104 b) may be identical in structure and operation to the key 178 on the interlocking coupling 164, and that the following description applies to the keys 178 and 150 on the interlocking coupling 164 and foot coupling 138, respectively.

The key 178 is between a first horizontal position allowing the key to be inserted into the recess 114 and a second vertical position for locking the key within the keyway 130 of the middle portion 118 of the recess 114. The horizontal and vertical references in the description apply when the interlocks 106 are horizontal with respect to the x-y plane. If the interlock is tilted, for example, about the y-axis, then the "horizontal" and "vertical" positions of the keys 178 will be adjusted accordingly.

The horizontal position of the key 178 is illustrated by the interlocking coupling 164 located to the right in fig. 15 and in the cross-sectional view of fig. 19. The key 178 in the vertical position is shown by the interlocking coupling 164 on the left in fig. 15, the cross-sectional side view of fig. 16 and 20. The interlocking couplings 164 of fig. 15 are shown in different orientations for illustration purposes only, and it should be understood that the left interlocking coupling 164 will be in a horizontal position to insert the interlocks 106 into the grooves 114 of adjacent modules 102, as explained below.

Generally, with the keys 178 of both interlock couplings in a horizontal position, the interlocks 106 engage the grooves 114 of modules 102 that are adjacent to each other in the x-direction, with one interlock coupling 164 inserted into each of the adjacent grooves 114. The interlock 106 may engage the rib 170 at an angle that matches the insertion angle of the upper and lower angled surfaces 122, 126. A chamfer 182 may be provided at the bottom of the lower rib 170 to make it easier for the rib 170 to be inserted into the groove 114.

While completion of the pivot-fit connection of the groove 114 and tongue 148 of the leveling foot 104 is facilitated by the moment generated by the weight at the coupling of the module 102, there is no such moment to facilitate coupling of the interlock 106 to the frame 112. Thus, the flange 174 and/or tongue 176 may be engaged by a tool 183 (shown in fig. 19 and in part in fig. 20), the tool 183 rotating the interlocking coupling 164 from a horizontal position to a vertical position. As the key 178 rotates (about the y-axis), it engages within the keyway 130 to pivot the rib 170 (about the x-axis). The ribs pivot from their insertion positions (parallel to the upper and lower angled surfaces 122, 124) to their final coupled positions (where the ribs 170 are substantially parallel to the planar surface and the x-y reference plane of the module 102).

The lead-in bevel 184 is defined by the key 178 increasing in thickness from narrow to full width. This introduced oblique angle allows the interlocking coupling 164 to pivot gradually about the x-axis from the angle of the groove 114 relative to the x-y reference plane to 0 degrees. This pivoting occurs as a result of interlock coupling 164 rotating along the axis of shaft 180 from its horizontal position to its vertical position.

A set of cutting teeth 188 are provided on the upper and lower portions of the key 178 of each interlock coupling 164 in the interlock 106. As the key 178 rotates from the horizontal position to the vertical position, the cutting tooth 188 cuts through the anodized layer in the groove 114 and makes electrical grounding contact with the aluminum or other metal of the PV module frame 112. Both interlock couplings 164 on the interlock 106 may include these sets of cutting teeth 188. Thus, in addition to locking adjacent modules 102 together, rotation of the interlock coupling 164 electrically couples the two electrical modules together. A ground coupling, described below, may connect the array in a grounded state.

The debris gap 186 on each end of the key 178 allows the teeth 188 to cut into the frame surface within the keyway 130 more effectively and provides a parking place for swarf generated by the cutting. The nubs 187 on the ends of the keys 178 also help align the keys by abutting the rear wall 132 at the distal end regions.

The flange 174 may include a detent 190 for engagement by a tool 183 to allow the interlocking coupling 164 to be quickly and simply rotated from a horizontal position to a vertical position. Upon final rotation, the catch 190 may be located on the bottom side of the interlocking coupling 164. This location and customized shape of the detents 190 makes it difficult to remove the interlock 106 from the module 102 without having the appropriate tools to improve the safety aspects of the system.

It is contemplated that some or all of the components of interlock 106 may be made of corrosion resistant materials or may include a corrosion resistant coating to prevent galvanic and/or moisture induced corrosion. Such corrosion protection may help prevent loss of ground continuity over time, as foot couplings 138 may provide ground engaging connections between adjacent PV modules.

Fig. 21-23 show respective side views of the interlock 106 attached to a pair of adjacent modules (one such module is visible in the side view). Fig. 21 shows the ribs 170 of the interlocking coupling 164 inserted between the upper and lower inclined surfaces 122, 126 of the frame 112. The rib 170 may be inserted at an insertion angle of the upper and lower angled surfaces 122, 126 to provide maximum clearance (i.e., distance m, fig. 4A) for the rib 170 to enter the groove 114. The width of the upper and lower ribs 170 taken together may be slightly less than or equal to the distance m. As indicated above, the chamfer 182 on the bottom surface of the lower rib may also aid in the initial insertion of the rib 170 into the groove 114. Upon initial insertion of the rib 170 into the groove 114, the key 178 is in a horizontal position and thus does not interfere with the insertion of the rib between the upper and lower inclined surfaces 122, 126.

Once the rib 170 is manually inserted, the tool 183 can then be used to rotate the interlocking coupling from the horizontal position to the vertical position as long as it travels between the upper and lower inclined surfaces 122, 126. Fig. 22 shows the interlocking coupling after partial rotation of the key 178, the end of the key 178 becoming more visible in the side view of fig. 22. Introducing the bevel 184 pulls the key 178 into the keyway 130 behind the inclined surfaces 122, 126. Thus, as the coupling 164 rotates, the coupling is pulled into the groove 114 and pivots from the initial position shown in fig. 21 to a final position in which the key 178 is fully engaged with the keyway 130. This final position is shown in fig. 23.

As indicated above, the spacing between the upper and lower angled surfaces 122, 126 as viewed by the rib 170 and the axis 180 may be the distance m described above in fig. 4A when the interlock 106 is first inserted into the groove 114. As key 178 is pulled into the groove by rotation of coupling 164, rib 170 and axis 180 pivot from the insertion angle to the final position parallel to the x-y reference plane as shown in fig. 23. In this position, the spacing between surface 122 and surface 126 as seen by rib 170 and axis 180 is a small distance n. In some embodiments, the outer diameter of the rib (together) and the axis may be slightly greater than or equal to the distance n, taking into account tolerance variations. For example, the diameter of the ribs and shaft along this dimension may be 0.005 "(which is less than distance m) and 0.005" (which is greater than distance n). In other implementations, the size of the ribs 170 and/or the axis 180 relative to the distances m, n may be different therefrom.

Pivoting the interlock coupling 164 from the position of fig. 21 to the position of fig. 23 results in a pivot-fit connection between the interlock 106 and the groove 114. In particular, the ribs 170 and/or the shaft 180 support and exert an upward force on the bearing portions 124 in the upper inclined surface 122 in the z-direction, and the ribs 170 and/or the shaft 180 support and exert a downward force on the bearing portions 128 in the lower inclined surface 126 in the z-direction. These forces elastically deform the frame 112 around the groove 114 (in the direction of arrow 151 in fig. 23) to account for any variability in the z-axis dimension of the track and/or shaft in the groove 114. This provides a solid state connection relative to the z-axis and prevents any relative vertical movement between the interlocks 106 and the corners of adjacent modules to which the couplings of the interlocks 106 engage. The keys 178 supporting the top and bottom slots 130a, 130b of the keyways 130 may additionally or alternatively prevent the corners of adjacent modules from moving relative to the interlocks 106 and to each other. Once the key 178 enters the recess 114, the interlock plate 168 may begin to pivot primarily about the bearing portion 124 as the interlock 106 rotates to its final position.

In one embodiment, to secure the interlock 106 to an adjacent module 102, the interlock coupling 164 in a first module 102 may be partially rotated to engage the key 178 of the coupling 164 partially within the keyway 130 of the first module. The interlocking second coupling element 164 can then be fully rotated from the horizontal position to the vertical position to fully engage the second coupling element within the keyway 130 of the second module 102. Rotation of the first coupling element can then be completed to complete the installation of the interlock 106. It should be appreciated that the installation of the interlock may be performed by other methods, such as, for example, fully inserting the first interlock coupling 164 and then fully inserting the second interlock coupling 164 or fully rotating each interlock coupling 164 immediately after insertion into the groove 114.

As indicated above, the key 150 in the leveling foot 104 may be affixed within the recess 114 in the same manner as described above with respect to the key 178 of the interlock 106. Thus, referring again to fig. 6 and 10, prior to seating the module 102 on the tongue 148 of the leveling foot 104a, the leveling foot 104b may be affixed within the groove 114 on the opposite side of the module 102 by inserting the key 150 into the groove 114 and rotating it, either manually or with a tool, as described above to engage the key 150 into the keyway 130.

Fig. 24 is a perspective view showing a pair of adjacent modules 102 connected with an interlock 106 as described above. Fig. 24 also shows leveling feet 104 of the support module 102. Fig. 24 shows the tongue 148 of the leveling foot 104 engaged within the groove 114 without the module engagement key 150. In some embodiments, the tongue for an interlocking coupling comprises a hook as described elsewhere in this disclosure. The leveling feet 104 shown in fig. 24 may be coupled, for example, at the front most surface of the array 100 (e.g., one of the leveling feet 104 shown in fig. 5). In alternative embodiments, the leveling feet 104 at the front of the array may have different configurations, with the key 150 inserted or omitted in place of the tongue 148. The module 102 may be detached from the array 100 by performing the reverse of the operation described above for mounting the module 102 to the array 100.

In some embodiments, PV modules 102 may be aligned with each adjacent module 102 in the x-direction. However, the interlocks 106 may operate even if the modules 102 are not perfectly aligned in the x-direction. Fig. 24A shows a plan view of four modules 102a, 102b, 102c, and 102 d. The modules 102a and 102b are adjacent to each other in the x-direction, but are not fully aligned. However, as described above, the interlock 106 may couple the modules 102a and 102b together. The interlock plate 162 can slide in and out over the interlock coupling shaft 180 to enable the rib 170 to properly contact the bearing portions 124, 128 of the recess 114 even in a misaligned condition as shown. The shaft 180 of the interlock coupling 164 and the rib 170 on the interlock 106 are long enough so that the key 178 on one side of the interlock 106 can engage within the recess of the module 102a and the key 178 on the other side of the interlock 106 can engage within the recess of the module 102b even if the interlock plate 162 is not parallel to the front edge of the module 102a or 102 b.

Any misalignment of the modules 102a and 102b may be assumed by the interlocks 106 and not transferred to the next row of modules 102c and 102 d. In particular, the modules 102c and 102d may be disposed on the tongues 176 of the respective interlock couplings 164 on the back side of the interlocks 106. As mentioned above, in the coupled position, the tongue still allows the module to move relative to the tongue in a direction parallel to the reference plane. Thus, the modules 102c and 102d may be aligned with each other on the tongue 176, and any misalignment of the modules 102a and 102b does not shift to the next row.

As described above, if the array 100 is disposed on a residential roof, the position of the leveling feet 104 along the x-dimension of the module 102 may be determined by the position of the rafters or joists below the roof. This is often not a smart alignment on the seams between adjacent modules (since the length of PV modules is often not the same as the standard spacing between rafters). Thus, leveling feet 104 may be used to support an array on rafters or joists, and interlocks 106 may be used to couple modules together at a seam. However, in other implementations, some rows of modules may need to be slid farther to the east or west than other rows of modules; such as using a four pitched roof where the array 100 fits better if it follows the angle of the ridge. In some embodiments, it may be desirable to orient some rows of modules 102 in the landscape orientation and others in the portrait orientation. In these cases, the interlock 106 may reside at the seam and/or at any point along the side of the PV module 102.

In still other embodiments, the array 100 is disposed on a support structure 103, the support structure 103 being specifically provided to support the array (e.g., such as a ground mounted array). In such embodiments, the installer is free to select the location of the supports in the structure 103 and can choose to align these supports with the seams between modules in the array. For such embodiments, a combined leveling foot and interlock may be used.

One embodiment of a combined leveling foot and interlock 191 is shown in fig. 25. While such assemblies can have a variety of configurations, in one example, the assembly 191 can include a foot 192 that includes a pair of double threaded studs 140 as described above with respect to the leveling foot 104. A pair of foot couplings 138 may be affixed to feet 192, spaced from each other on stud 140 so that they may be engaged in the corners of the first and second pairs of modules. The first coupling element 138 may be attached to the corner of a first pair of adjacent modules in the y-direction as described above. Likewise, second coupling element 138 in the span may be coupled to a corner of a second pair of adjacent modules in the y-direction as described above. Thus, a single assembly may be used to secure the corners of four adjacent modules together, support those modules at a desired height above the support surface, and electrically ground those modules together.

The present techniques may include additional couplings that fit within the grooves 114 in other embodiments. In some embodiments, a common element of all of these additional couplings may be a key (e.g., reference key 178) as described above that engages with the groove 114 to form a mechanical and electrical connection with the PV module frame 112. In other embodiments, the common element may be a tongue (e.g., reference tongue 148) as described above or any protrusion capable of engaging with the groove 114.

As noted above, one such coupling may be a ground coupling 194 as shown in fig. 26. Ground couplings 194 are used to connect ground wires (not shown) to one or more PV modules 102 of array 100. The ground wire passes through the in-layer projection channel 195 and the termination screw 196 can then be rotated until safe grounding is completed using the ground wire. The ground coupling 194 may also include other features of the couplings described above, such as a threaded bore 197 for receiving a double threaded stud that allows the ground coupling to be supported on the support structure 103 via the base 134 described above with respect to the leveling foot 104. The ground coupling may also include a key 178 for locking within the keyway 130 in the groove 114 to couple the ground coupling 194 to the modules 102 of the array 100, as described above.

It may happen that other accessories need to be attached to the modules 102 of the array 100. Figure 27 shows other couplings for attaching such accessories to modules of the array (referred to as accessory couplings 198). The accessory couplings 198 have keyways 130 for locking in the grooves 114 as described above to attach the accessory couplings 198 to the keys 178 of the modules of the array 100. The accessory coupling may include the flange 174, the key 178, and a shaft 180 and a detent 190 between the flange 174. Each of these components may be identical in structure and operation to similar components described above for interlocking coupling 164.

The flange 174 may be used to positively retain any type of assembly against the PV module frame 112 once the accessory coupling 198 is rotated from its horizontally inserted position to its vertically locked position. Referring to fig. 28, the accessory coupling 198 may, for example, hold an assembly 199 for a PV module inverter, or any other type of electronic device that may be mounted and possibly grounded to the PV module frame 112. In the embodiment of fig. 28, assembly 199 may be held under PV module 102. The accessory coupling 198 may also mount and ground a wire splice box or wire management system. The present application encompasses any device that can be mounted to the PV module frame 112 with a coupling device as described above and/or below.

In the above-described embodiments, the PV module 102 includes a frame 112, the frame 112 having a novel groove design for engaging with tongues and/or keys and shafts having different couplings. However, those skilled in the art will recognize that generally female parts may be exchanged for generally male parts, and vice versa, and thus other embodiments of the present technology may operate in conjunction with PV modules 102 that do not have a groove 114. For example, fig. 29 and 30 show a wrap-around leveling foot 204, wherein the couplings or brackets of the leveling foot 204 wrap around the upper and lower surfaces of a pair of PV modules 202 (without grooves 114) that are adjacent along the y-axis. It should also be appreciated that in other implementations, the wrap-around leveling foot 204 may be used in conjunction with the module 102 having the groove 114.

The wrap around leveling foot 204 may include a base 206 and a coupling 208 attached to the base 206 by a double threaded stud 210. The base 206 and stud 210 may be the same as the embodiments of the base 134 and stud 140 described above with respect to the leveling foot 104. In other embodiments, the studs 210 are eliminated and the base 206 is an integral part of the base 214. The foot coupling 208 may include a hole 209 for receiving a stud 210, and rotating the stud 210, for example by a tool within a tool receiving recess 212 in the stud 210, may raise and lower the coupling 208 relative to the foot.

The coupling 208 includes a base 214 having a channel 216 and a threaded bore 218. The base 214 includes a first side 220 on a first side of the channel 216 and a second side 222 on an opposite side of the channel 216. The horizontal portion of the base 214 on the first side 220 may have a uniform vertical thickness t. The horizontal portion of the base 214 on the second side 222 has a first thickness v that is less than the thickness t and a second thickness t that is the same as the thickness t on the first side 220. The inclined surface 223 may be configured to connect a section of the side 222 having the thickness v to a section of the side 222 having the thickness t. The inclined surface 223 is uppermost at a bearing portion 237, which bearing portion 237 supports the module 202 once the module is pivoted down to its final position.

Coupling 208 also includes a cap 224 and a cap screw 226. The cap 224 may be seated within the channel 216, and the cap screw 226 may be fit down through the cap and into the threaded hole 218 in the base 214. As indicated above, a hole 209 is formed through the coupling 208 (including through the base 214 and the cap 224) for receiving the double threaded stud 210. The hole 209 may be threaded through the base 214, but may be larger in the cap 224 so that the stud 210 engages the base but not the cap. Thus, rotating the studs 210 raises and lowers the base 214 and the cap supported on the base, but does not act independently on the cap.

The cap 224 also includes a second hole 228, a counter bore for receiving the cap screw 226. The cap 224 includes a cap section 230 and a shaft section 232. The shaft section 232 fits snugly within the channel 216 and the screw 226 fits through the hole 228 in the cover 230 and the shaft 232 into the threaded hole 218 in the base 214 to mount the top cover to the base. A retaining ring may optionally be provided on the cap screw 226 below the shaft 232.

To secure a pair of modules 202 to the leveling feet 204 and to each other along the y-axis, a first module 202a is inserted between the top cover 224 and the base 214 on a first side 220 in the x-y reference plane. The cap 224 may be loosely affixed to the base 214 at this point, or affixed to the base after the module 202a is engaged with the side 220 of the base. Once the module 202a is positioned on the base 214, the top cover screws 226 may be tightened to securely fix the module 202a to the wrap around leveling feet 204 on the first side 220 between the top cover 224 and the base 214. The underside of the cap section 230 of the cap 224 may include ridges 236 to ensure good gripping of the module 202a by the cap 224 when the cap is tightened down.

The base 214 may include one or more electrical ground teeth 238, for example, in the shape of an inverted v, for cutting through the anodized layer of the module 202 a. As top cap 224 is tightened down against module 202a, teeth 238 bite through the anodized layer to engage the aluminum or metal layer of module 202a to provide electrical ground for module 202 a. In other embodiments, the ridges formed in the bottom side of the cap section 230 may alternatively or additionally cut into and through the anodized layer to engage an aluminum or other metal layer below the anodized layer to provide electrical grounding of the module 202 a.

Once the first module 202a is attached and the top cover 224 is in place, the second module 202b may be inserted at an angle between the cover section 230 and the ramp 223. The inclined surface 223 may be disposed at an angle as described above with respect to the groove 114. The insertion angle of the ramp 223 allows the module 200b to be simply inserted at an angle that matches the insertion angle and then pivoted down onto the pivot point into the x-y reference plane to engage the module 202b between the base 214 and the top cover 224 (which is fixed in place about the first module 202 a).

The distance between the outer edge of the cover section 230 and the inclined surface 223 is at least as large as the thickness of the module 202 in a direction perpendicular to the inclined surface 223. Once inserted as far as possible at the insertion angle, the module 202b is pivoted downward to reside in the x-y reference plane of the array, creating a pivot-fit connection similar to that described above. Those skilled in the art will recognize that the pivot-fit connection of fig. 30 still allows for footprint dimensional variations because the module 202b, once pivoted into position, is not significantly constrained within the y-axis, but is substantially constrained in the z-axis by the top cover 224 and base 134. Portions of the second side 222, such as the sloped surface 223 for example, may include one or more electrically grounded teeth 238 as described with respect to the first side 220. The teeth 238 maintain reliable electrical contact even with small variations in the position of the module 202b along the y-axis. The wrap around leveling feet 204 allow PV modules without grooves to be coupled and electrically grounded together and supported on a support surface. Also, having the top cap 224 threaded down onto the module allows the wrap around leveling feet 204 to be used with modules of different thicknesses. In other embodiments, the cap screw 226 may be omitted and the cap 224 may be formed integrally with the base 214 or otherwise permanently affixed to the base 214. Such embodiments may be used in conjunction with modules 202 having a single uniform thickness.

Fig. 30A shows an alternative embodiment of a wrap around leveling foot 600. The wrap-around leveling foot 600 is similar to the wrap-around leveling foot 204, but the wrap-around leveling foot 600 may be formed of a unitary construction without any movable components. In particular, the wrap-around leveling foot 600 can include a bracket 602, the bracket 602 including a horizontal base portion 602a and a vertical portion 602 b. The base portion 602a may include an opening 604 for mounting the leveling foot 600 to the support structure 103. In an embodiment, the height of the wrap around leveling foot 600 is not adjustable so that the leveling foot 600 may be best suited for connection to a straight surface (such as the track 256 described below, e.g., with respect to fig. 38). However, in other embodiments, the leveling feet 600 may be connected to the support structure 103 by other methods.

Vertical portion 602b includes upper flanges 606 and 608 extending from opposite sides of vertical portion 602b, and lower flanges 610 and 612 extending from opposite sides of vertical portion 602 b. The lower flange may be angled upward at an angle (e.g., the insertion angle described above) from its connection point with vertical portion 602 b.

As described above with respect to fig. 29, a first PV module (not shown in fig. 30A) may be inserted at an angle between upper flange 606 and lower flange 610. The angle may be the insertion angle of the lower flange 610 and may be, for example, 15 °, but may be other angles in other embodiments. Once inserted such that the PV module abuts vertical portion 602b, the PV module can be pivoted down to the x-y reference plane until the module supports bearing portion 616 in upper flange 606 and bearing portion 618 in lower flange 610. At this point, the PV module may be secured to wrap around foot coupling 600 and restricted from movement in the vertical direction. Which can still be adjusted in the reference plane. A second PV module can be affixed to wrap around foot coupling 600 in the same manner on the opposite side of vertical portion 602. The wrap around module 600 may also include ground teeth, such as the ground teeth 238 described above with respect to fig. 29.

Fig. 31 and 32 are perspective and side views of a wraparound interlock 240 in accordance with embodiments of the present technique. The wraparound interlock 240 is similar in construction and operation to the wraparound leveling foot 204, and components having the same reference characters in fig. 29 through 32 have similar functions. One difference is that although the wrap around leveling feet 204 are provided to couple a single pair of modules adjacent to each other in the y-direction, a wrap around interlock 240 is provided to couple two pairs of modules adjacent to each other in the x-and y-directions. Thus, the base 214 of the wraparound interlock 240 is similar to the base 214 of the wraparound leveling foot 204, but the base 214 of the interlock 240 is longer to span the corners of four modules that are adjacent in the x-direction and the y-direction.

A second difference may be that the base 206 and stud 210 of the wrap-around leveling foot 204 may be omitted from the interlock 240. Thus, in some embodiments, wraparound interlock 240 may couple the four corners of adjacent modules together, but not support those modules on support structure 103. In other embodiments, the wrap-around leveling foot 204 and the wrap-around interlock 240 may be combined such that the base 206 and stud 210 of the wrap-around leveling foot may be added to the structure of the wrap-around interlock 240. The resulting coupling couples the corners of four adjacent modules together and supports those modules at an adjustable height above the support surface.

In light of the above, the wraparound interlock 240 shown in fig. 31 and 32 may include a pair of caps 224 disposed within the channel 216. Alternatively, the wraparound interlock 240 may include a single cap 224 that spans the entire length of the base 214. In such embodiments, the top cover 224 may have a single top cover screw 226 for screwing the top cover down onto the four corners of adjacent PV modules, or a pair of top cover screws that pass through a pair of top cover screw holes for screwing the top cover 224 down onto the four corners of adjacent modules. Once the first pair of modules 202a is inserted into the first side 220 of the base 214, the top 224 may be screwed down. Thereafter, a pair of second modules may be inserted at an insertion angle to the second side 222 of the base 214 and pivoted downward to a final coupled position (shown in fig. 32) to create a pivot-fit connection similar to that described above. As noted above, the screw-down caps may be omitted to facilitate operation of the integrally formed caps in conjunction with a module having a single uniform thickness.

Figures 32A through 32C illustrate other embodiments of wraparound couplings 400. Coupling 400 of this embodiment may include a base plate 402 and a screw 404. Although a single screw 404 is shown in figure 32A, wraparound coupling 400 may also include a second screw for engaging a second pair of modules as explained below. The screw 404 may have a head 406. Wraparound coupling 400 may also include ground teeth 412 on a first side of baseplate 402 and ground teeth 410 on a second side of baseplate 402.

Figure 32B shows a side view of wrap-around coupling 400 with a pair of modules 202a and 202B connected together in the y-direction via screws 404. A second screw 404 (not visible in the side view of fig. 32B) would similarly connect together a second pair of modules (not visible in the side view of fig. 32B) that are adjacent to modules 202a and 202B in the x-direction. In operation, first module 202a is urged against a first side of wraparound coupling 400 and screws 404 are tightened down until module 202a is held by head 406. Thereafter, the second module 202B may be introduced, for example, at an insertion angle shown in dashed lines in fig. 32B, until contacting the stop 416 formed on the substrate 402. Second module 202b may then be pivoted downward as described above to couple second module 202b to wraparound coupling 104. The grounding teeth 412 may engage metal within the first module 202a when the screw 404 is tightened down, and the grounding teeth 410 may engage metal within the second module 202b when the module 202b is pivoted down to its final position.

Figure 32C illustrates an embodiment of a wraparound coupling 420. Coupling 420 is similar to coupling 400 shown in figures 32A and 32B, but in figure 32C, wraparound coupling 420 is adapted to be supported on a support structure as in support structure 103 described above. For this purpose, the wrap around coupling 420 includes a base 422 supported on the support structure as in the support structure 103 and studs 424 which may be any of the studs described above for mounting the coupling on the base. Modules 202a and 202b may be attached to wraparound coupling 420 as described above with respect to wraparound coupling 400.

Fig. 32D shows an alternative embodiment of a wraparound interlock 620. The wraparound interlock 620 is similar to the wraparound interlock 240 of fig. 31, but the wraparound interlock 620 may be formed of unitary construction without any movable components. In particular, the wraparound interlock 620 can include a vertical portion 622, upper flanges 626 and 628 extending from opposite sides of the vertical portion 622, and lower flanges 630 and 632 extending from opposite sides of the vertical portion 622. The lower flange may be angled upward from its connection point with the vertical portion 622 at an angle (e.g., the insertion angle described above).

As described above with respect to fig. 31, wraparound interlock 620 may be inserted over a first PV module (not shown in fig. 32D) at an angle where upper flange 626 and lower flange 630 are mounted over the upper and lower edges of the frame. The angle may be the insertion angle of the lower flange 630 and may be, for example, 15 °, but it may be other angles in other embodiments. Once inserted such that the PV module abuts the vertical portion 622, the interlock 620 can pivot downward, the PV module supporting the bearing portion 636 in the upper flange 626 and the bearing portion 638 in the lower flange 630. At this point, wraparound interlock 620 may be secured to the PV module. A second PV module can be affixed to the wraparound interlock 620 on the opposite side of the vertical portion 622. Wraparound interlock 620 may also include ground teeth, such as ground teeth 238 described above with respect to fig. 31.

Fig. 33 shows a perspective view of the PV array 200 assembled together using wrap-around leveling feet 204 and wrap-around interlocks 240. As can be seen, the wrap-around leveling feet located between adjacent modules 202 in the y-direction are used to couple those modules together and support the array 200 on the support structure 103. A wraparound interlock 240 between adjacent modules in the x-direction and adjacent modules in the y-direction may be used to couple the corners of four adjacent modules together. Although the embodiment of fig. 33 shows the foot 206 on the interlock 240, other embodiments contemplate the use of the interlock 240 as shown in fig. 31 in reverse. In an alternative embodiment, the first side 220 or the second side 222 may be omitted from the wraparound interlock 240 such that it connects only adjacent modules in the x-direction and not adjacent modules in the y-direction. In view of the above disclosure, those skilled in the art will appreciate that in other embodiments, other couplings, such as electrically grounded couplings and accessory couplings, may be configured as wrap-around couplings.

To this end, the PV module has been described as a laminate 110 within a frame 112. However, it may happen that the solar array is composed of PV laminates 110 without a frame 112. Figures 34-36 illustrate other embodiments of couplings for coupling laminate plates 110 without a frame together. The laminate 110 is sometimes still referred to as a PV module 110 because it includes electrical connections. The frameless interconnect 250 can be used to couple together the corners of a pair of frameless laminates in the y-direction, a pair of laminates in the x-direction, or four laminates adjacent in both the x-direction and the y-direction.

The frameless interconnect 250 generally includes a coupling 252 affixed to a mounting screw 254. The mounting screws 254 are in turn affixed within the rails 256 of a rail system laid down on the support structure 103. The coupling 252 may include a first side having a first groove 258 formed into the coupling along the side of the coupling and angled inward and downward from the outer surface. The angle may be, for example, a 15 insertion angle, but may vary in other embodiments of the invention. The coupling 252 may similarly include second opposing sides having second grooves 262 configured as mirror images of the first grooves 258, i.e., along the sides of the coupling and angled downward into the coupling at, for example, an angle (e.g., 15 °).

The grooves 258 and 262 receive the bare laminate, and the grooves may include a curved liner 264, such as rubber, to prevent cracking of the edges of the laminate received within the grooves. To install the PV laminate in the first or second recesses 258, 262, the laminate is inserted at an angle that matches the insertion angle of the recesses, and then pivoted downward to create a pivot-fit connection. The coupling 250 includes bearing portions 259, the bearing portions 259 supporting the PV laminate 110 on the first and second sides of the coupling once the laminate is pivoted down to its final position.

The coupling 252 may be affixed to the support structure 103 via mounting screws 254 and rails 256. The coupling 252 may be supported on the mounting screw 254 in a variety of ways. In a first embodiment, the coupling 252 may have threads that engage the threads of the mounting screw 254 such that rotation of the mounting screw 254 relative to the coupling 252 causes the coupling to move up or down along the mounting screw. In a second embodiment (shown in fig. 34), once the screw 254 is installed within the track 256 as explained below, the spacing between the head of the mounting screw 254 and the track 256 may be approximately equal to the height of the coupling 252. In such embodiments, the position of the coupling 252 is then fixed when the screw 254 is installed in the track. Other embodiments may be similar to the embodiment described above and shown in fig. 34, but the spring biasing mechanism may be positioned on the mounting screw. The spring-biasing mechanism may have a first end biased toward the lower surface of the coupling 252 and a second end biased toward the upper surface of the track 256. Therefore, the coupling member 252 is pressed upward toward the head 254a and a portion of a mounting screw (described later) mounted in the rail is biased toward the inner upper surface of the rail.

In some implementations, the frameless interconnect 250 is mounted within a rail 256, which rail 256 can be affixed to a support surface along the x-axis and/or the y-axis. The rails 256 may be positioned in locations corresponding to seams between adjacent PV laminates 110, but need not correspond to two axes in some embodiments. As seen in fig. 35, the track 256 may have a substantially C-shaped cross-section. The track 256 may include opposing surfaces 260 and 262 and be wider than a keyway 264 accessible through the opposing surfaces 260 and 262.

In one embodiment, the mounting screw 254 may include a key 268 at its base that has a length greater than its width. When the width dimension of the key 268 (visible in fig. 34) is aligned between the opposing surfaces 260 and 262, the width dimension can fit between the opposing surfaces 260, 262 to allow the mounting stud to be inserted into the keyway 264. The mounting stud may then be rotated 90 ° such that the length dimension of the key 268 is locked within the keyway 264. The length dimension of keyway 264 is visible in the cross-sectional view of fig. 35. Those skilled in the art will appreciate various other mechanisms for supporting the coupling 252 on a support surface. In other embodiments, a foot and a double threaded stud, such as described above with respect to leveling foot 104, may be provided and coupling 252 mounted on the stud. In such embodiments, the track 256 may be omitted.

Fig. 36 shows a plan view of an array that can be formed using frameless interconnects 250. It shows a plurality of frameless interconnects, each connecting four adjacent PV laminates 110 together at their corners. Fig. 36 also shows a track 256 oriented in the y-direction. In other embodiments, the track 256 may be oriented in the x-direction. In other implementations, the frameless interconnect 250 can be bisected along the y-axis to link only two adjacent modules along the y-axis, or the frameless interconnect 250 can be bisected along the x-axis to link only two adjacent modules along the x-axis.

A PV array such as described above with respect to fig. 1 may lie in a flat x-y reference plane and on an inclined support structure 103, such as a roof of a residence, for example. It should be understood that the PV array may also be disposed on a flat surface, such as a commercial rooftop or ground mounted array, for example. Fig. 37-39 illustrate a tilt interlock 280 that may be used, for example, to mount PV modules on a flat surface, where each module is disposed at an oblique angle relative to the support surface and the x-y reference plane to optimize the angle of incidence of solar radiation. It should be understood that the PV array in the x-y reference plane of fig. 1 may be mounted on a flat surface, and it should be understood that the PV array described with respect to fig. 37-39 may be mounted on an inclined surface.

The tilt interlock 280 may be configured to operate with modules having angled grooves 114 (as shown in fig. 37 and 38) or modules without angled grooves (as shown in fig. 39). Referring initially to fig. 37 and 38, interlock 280 is shown to include a first upright portion 282 spaced from and generally parallel to a second upright portion 284. The first and second upstanding portions may be integrally formed or otherwise connected to the substrate 286. The first upright portion 282 extends away from the substrate 286 a greater distance in the z-direction than the second upright portion 284. The tilt interlock 280 may be formed, for example, from extruded or rolled aluminum or some other metal, such as rolled steel.

The first upright portion 282 may include a pair of holes 288 for receiving a first set of coupling members 290. The second upright 284 may include a pair of apertures 292 for receiving a second set of coupling members 294. And the substrate 286 may include mounting holes 296 for receiving substrate couplings 298. The substrate 286 may also include a pair of alignment tongues 300 stamped from the substrate and extending downward to align the tilt interlocks with the tracks as explained below. The length of the substrate between the first upright portion and the second upright portion may be selected to prevent the first upright portion 282 from casting a shadow on a PV module mounted to the second upright portion 284.

A first pair of PV modules (one of which is visible in fig. 38) adjacent to each other in the x-direction can be affixed to the first upright 282 via a first set of couplings 290. The opposite end (not shown) of the first pair of PV modules is supported on the second upright portion 284 of the next tilt interlock 280. Thus, the PV module is mounted at an angle that is a function of the difference in height of the first and second upright portions 282, 284 and the length of the PV module. In some implementations, this angle may vary between 1 ° and 30 ° and may be, for example, 10 ° (note that this angle is independent of the insertion angle discussed above and below with respect to the pivot-fit connection that may be associated with the final plane of the PV array or a row of PV modules). In some embodiments, a first pair of PV modules, when coupled to the first upright portion 282, can form a right angle on the first upright portion 282. When the PV modules are angled as described above, the first upright portion 282 may also be angled relative to the vertical at the same angle that the PV modules form with the horizontal.

As shown, the upright 282 includes a first set of couplings 290, and in some embodiments, each of the first set of couplings 290 can include an accessory coupling as described above with respect to fig. 27. As described above, such couplings can be installed through the holes 288 with the keys engaging the grooves 114 of the first pair of modules, and the flanges supporting the surfaces of the uprights 282. In some embodiments, upright 282 further includes rib 170 as described above.

A second pair of PV modules (one of which is visible in fig. 38) adjacent to each other in the x-direction can be affixed to the second upright 284 via a second set of couplings 294. The opposite end (not shown) of the second pair of PV modules is supported on the first upright portion 282 of the next tilt interlock 280, thus mounting the second pair of PV modules at the same angle as the first pair of PV modules. Second upright 284 may also be inclined at the same angle of inclination (e.g., 10 °) so that second upright 284 is at a right angle to the completed coupling between the second pair of modules.

The second upright portion 284 may include a pair of coupling members 294, the coupling members 294 having tongues such as the tongues 148 described above with respect to the leveling foot 104, for example. To mount the second pair of PV modules 102b on the respective tongues of the second set of coupling elements 294, the modules are inserted on the tongues at an angle equal to the angle of inclination plus the angle of insertion. If the angle of inclination is 10 ° and the insertion angle is 15 °, PV module 102b can be inserted at an angle of 25 ° to the horizontal. Again, these angles are by way of example only. At this angle, the upper and lower inclined surfaces 122, 126 in the groove 114 of the PV module 102b are parallel to the tongue 148 of the respective coupling 294 and aligned with the tongue 148. Once engaged on the tongue of the second coupling element 294, the PV module 102b can be pivoted downward to a final tilt angle to provide the aforementioned pivot-fit connection of the second pair of modules 102b with the tilting coupling element 280. The tongue on coupling 294 may include grounding teeth as described for tongue 148; other embodiments contemplate no ground teeth on the tongue of coupling 294.

The tilt interlock 280 may be mounted to the respective support surface by various fastening mechanisms. In the illustrated embodiment, the tilt interlock 280 is mounted to the support structure 103 via a track 256 such as described above with respect to fig. 35. In such embodiments, the substrate coupling 298 may include a key 302 that may be installed within a keyway and then rotated to engage a key within the track 256. A pair of alignment tongues 300 may also be mounted downwardly within the channel defined between the opposing surfaces 260, 262 in the track 256 to align and maintain the tilt interlock 280 in the proper orientation relative to the track 256.

The track 256 in any of the above embodiments may be mounted directly to a support surface, which may be, for example, a flat top or ground mounted support system. Alternatively, the track may be supported on the support block so as to be spaced from the support surface. A wide variety of other methods for mounting the tilt interlock 280 to a support surface will be apparent to those skilled in the art. In one other embodiment, the tilt interlock 280 may include a foot and a double threaded stud, such as described above with respect to the leveling foot 104, for example. In such embodiments, the base 286 may include a threaded bore for receiving a double threaded stud. In this example, the substrate coupling 298 and the track 256 may be omitted. In other embodiments, tilt interlock 280 is held down via the ballast material and/or the tray with ballast material therein.

Fig. 39 shows a wraparound tilt interlock 310 that may be similar in structure and operation to tilt interlock 280 except that it requires a pivot-fit connection on both ends of each PV module 102. The interlock 310 may be configured to operate in conjunction with PV module frames that do not include the recess 114 or have frameless laminates. Instead of the first set of coupling members 290 and the second set of coupling members 294, the wraparound tilt interlock 310 may include a first set of clamping arms 312 in the first upright portion 282 and a second set of clamping arms 314 in the second upright portion 284. The bottom arms of at least first set of gripper arms 312 and second set of gripper arms 314 may be angled upward at an insertion angle as described above, which may be, for example, 15 °. The insertion angle is here relative to the first and second upright portions 282, 284, which as explained above are set at an oblique angle (such as 10 deg., for example) relative to the vertical.

To install a first pair of PV modules (one such module visible in the side view of fig. 39) positioned alongside one another on upright 282 along the x-direction, the modules are introduced at an approach angle that matches the insertion angle minus the angle of inclination of the first set of gripper arms 312. If for example the insertion angle is 15 and the inclination angle is 10, this net angle will be 5 to the horizontal. It is to be understood that these angles are provided by way of example and that changes may occur in other embodiments. Once the PV module is inserted between the first set of clip arms 312, it can be pivoted downward at an oblique angle to its final orientation to provide a pivot-fit connection. The first set of gripper arms 312 may include bearing portions 316, 319, the bearing portions 316, 319 supporting the PV module when rotated to its final position to secure the PV module between the gripper arms 312. In some embodiments, the bearing portions may include cutting teeth to provide an electrical ground connection between the modules in the first pair of modules. In some embodiments, when an upper connection is made, the interlock 310 is pivoted into place on the module 102, and the module 102 is dropped into the lower connection and pivoted downward, thereby enabling such quick continuous operation in the north-south orientation.

To install a second pair of PV modules (one such module visible in the side view of fig. 39) positioned alongside one another on upright 284 along the x-direction, the modules are introduced at an approach angle that matches the insertion angle plus the angle of inclination of the second set of gripper arms 314. If for example the insertion angle is 15 deg. and the inclination angle is 10 deg., the net angle will be 25 deg. from the horizontal. It is to be understood that these angles are provided by way of example only and that changes may occur in other embodiments. Once the PV module is inserted between the second set of gripper arms 314, it may be rotated downward at an oblique angle to its final orientation. The second set of clamping arms 314 may include bearing portions 318, 319, the bearing portions 318, 319 supporting the PV module when rotated to its final position to secure the PV module between the clamping arms 314. In some embodiments, the bearing portions may include cutting teeth to provide an electrical ground connection between the modules of the first pair of modules.

Fig. 40 shows a plan view of an array of PV modules assembled together using tilt interlocks 280 or wraparound tilt interlocks 310. In some embodiments using a trough rack and tilt interlock 280, a first column of tilt interlocks may be mounted to the track 256 with the interlocking tongues directed inwardly toward the array. Thereafter, a pair of PV modules 102 may be dropped onto the tongues of the second set of coupling elements 294 in the first row of tilt interlocks 280. The PV module 102 can be pivoted downward to its final tilted position. At this point, the second row of tilt interlocks 280 may then have the keys of the first set of couplings 290 inserted into adjacent grooves in the PV module frame. The second row of tilt interlocks may then be secured to track 256. The process may then be repeated for the remaining PV modules in the y-direction.

As can be seen in fig. 40 and as described above, tilt interlocks 280 may be used to join the corners of four PV modules that are adjacent along the x-axis and the y-axis. In other embodiments, tilt interlock 280 may bisect along the y-axis to join only two adjacent modules along the y-axis, or tilt interlock 280 may bisect along the x-axis to join only two adjacent modules along the x-axis.

In some of the embodiments described above, the particular couplings have been described as being coupled along either the y-axis or the x-axis. However, it should be appreciated that in other embodiments, any coupling may be used for coupling along the y-axis and/or the x-axis. Embodiments of these couplings include tongues, keys, or brackets used in any of leveling feet 104, interlocks 106, wrap around leveling feet 204, wrap around interlocks 240, frameless interconnects 250, tilt interlocks 280, and wrap around tilt interlocks 310. Fig. 41 illustrates one such example. In the above embodiments, the attachment along the y-axis has used a tongue. In the embodiment of fig. 41, the first and second tilting couplings 326, 328 each comprise a tongue 320 for connecting PV modules in the x-direction.

In the embodiment of fig. 41, PV module 102 is tilted at an angle in its final position, as described above with respect to fig. 37-40. Thus, the first and second tilting couplings 326, 329 may be oriented along the y-direction, and the first tilting coupling 326 may extend a shorter distance away from the support surface than the second tilting coupling 328. The tilting coupling may be affixed to the support surface by any of the attachment systems described above.

To mount the next module 102 onto the tongues 320 of the first and second tilting couplings 326, 328, the module can be introduced into a tilting coupling that is tilted about the x-axis and the y-axis. That is, as explained above, to rest on the tongue 320, the PV module is angled at an insertion angle (which may be, for example, 15 °). Since the tongues 320 to which the PV modules are coupled lie along the y-axis, the module 102 may be angled at 15 ° about the y-axis so that the inclined surfaces 122, 126 of the groove 114 of the module 102 align on the tongues 320 in the first and second inclined couplings.

If the module 102 is laid flat (i.e., in the x-y reference plane), this would only be the angle applied to the PV module 102 to couple it to the tongue 320 of the couplings 326, 328. However, in this embodiment there is also a tilt angle applied to the module (the first tilt coupling 326 is shorter than the second tilt coupling 328). Thus, the module must also be tilted at an oblique angle to mate with the tongue 320. The angle of inclination is about the x-axis and may be, for example, 10 °. Thus, at these angles in this example, the module may be angled at 15 ° about the y-axis and 10 ° about the x-axis to properly orient the module to fit over the tongue 320. After mating over the tongue 320, the module 102 may then be tilted downward about the y-axis at an angle of 0 degrees relative to the y-axis to set the module in the final coupled position, tilted at a tilt angle about the x-axis.

In some of the embodiments described above, the oppositely facing portions of the couplings include tongues or keys, but not both. In other embodiments of the present technology, a single coupling may include a pair of keys or a pair of tongues. Such an embodiment is shown, for example, in fig. 42. In the embodiment of fig. 42, double bond coupling 322 is shown with flange 324. A first key 327 and shaft 329 extend from a first side of the flange 324, and a second key 330 and shaft 332 extend from a second side of the flange 324. Each of the keys 327 and 330 may be as described above, for example, with respect to key 178.

Figure 43 shows one example of mounting the array 100 using a double key coupling 322, where the double key coupling 322 is shown to also include an extension 336 to the flange 324. Once a pair of modules 102 are positioned adjacent to each other in the x-direction or the y-direction, the double key coupling 322 may be slid between the modules such that the keys 327, 330 are seated within the grooves 114 of respective adjacent modules 102. The keys may slide between the modules 102 and into the grooves 114 of the respective modules when in a horizontally inserted position. The extensions 336 may then be used to help rotate the coupling 322 so that the keys 327, 330 rotate to a vertical position and engage within their respective grooves 114, thereby coupling the modules 102 together.

In other embodiments, instead of the double key coupling 322 sliding into an adjacent module 102, the coupling 322 may be positioned within the groove 114 of the first module 102 with the first key 327. Thereafter, the second module may be moved into position to insert the second key 330 into the recess 114 of the second module. The extension 336 may then be used to engage the key in the vertical position as described above. A coupling having a pair of oppositely facing tongues may also be provided.

Fig. 44-48 illustrate other support couplings in the form of a front angled foot 440 (fig. 44 and 45) and a rear angled foot 450 (fig. 46). The front and rear angled feet 440, 450 may be identical to one another, except that the bracket 442 used in both feet 440, 450 may have an upwardly extending portion 442a that is longer in the rear angled foot 450 than in the front angled foot 440. The bracket 442 may be formed, for example, from 1/8 inch steel plate that is bent to form an upwardly extending portion 442a and a horizontal portion 442 b. In other embodiments, the stent 442 may be formed of different materials and formed to different thicknesses.

The upwardly extending portions 442a on the feet 440 and 450 can include openings for receiving the couplings 444, the couplings 444 having tongues 446 and keys 448 extending from opposite sides of the flange 452. The type and configuration of tongue 446 may be the same as tongue 148 described above, and the type and configuration of key 448 may be the same as key 150 described above. The flange 452 as shown has a hexagonal shape that matches the shape of the openings in the upwardly extending portions 442a of the feet 440, 450. The flange 452 can, for example, be molded into the opening to provide a tight and permanent mounting of the coupling 444 to the holder 442. In other embodiments, the flange 452 and the opening can have other corresponding shapes.

As shown in fig. 47 and 48, the front and rear angled feet 440, 450 may be adapted to connect to PV modules 102 all side-by-side along the x-axis. As can also be seen in these figures, the PV modules may be tilted, for example, by 10 ° relative to the support structure 103, as explained above, for example, with reference to fig. 37-40. When the couplings enter between the modules along the x-axis, and when the modules tilt about the x-axis, the couplings 444 may similarly tilt about the axial centers of the couplings 444. This feature is illustrated, for example, in fig. 45, where fig. 45 illustrates the use of a coupling inclined at an angle of 10 ° in the embodiment of fig. 47. The angle of inclination of coupling 444 may be set to match the angle of inclination of PV module 102.

The tilt in the PV module 102 may be provided by upwardly extending portions 442a of different lengths of the forefoot 440 and the rearfoot 450, as can be seen in fig. 47 and 48, for example. To insert the feet 440, 450, they may be generally oriented parallel to the groove 114 in the frame 112 such that the key 448 is oriented in the insertion position described above, for example, with respect to fig. 21. This initial insertion position is shown in phantom for legs 440 and 450 in FIG. 47. The foot can then be rotated 90 ° to engage the key 448 within the groove 114 as described above, for example, with respect to fig. 22 and 23. Once a pair of front feet 440 and a pair of rear feet 450 are locked onto a first PV module, another PV module adjacent in the x-direction may fall on the tongues 446 of the front and rear feet as described above, for example, with respect to fig. 41.

To remove the foot 440 or 450, the foot may be rotated 90 back to the initial insertion position shown in phantom in FIG. 47 and pulled outward from the groove 114. If the modules are mounted adjacent to each other along the x-direction as shown in fig. 48, it is not possible to pull the feet straight out of the grooves 114. In such instances, to remove the feet 440, 450, the feet may be rotated back toward the initial insertion position. The horizontal portion 442b may contact the next adjacent module as the foot is rotated back toward the initial insertion position such that the foot cannot be rotated back 90 to the initial insertion position. However, the foot may be rotated sufficiently to release the key 448 from the groove and allow the foot 440 and/or 450 to then slide out of the end of the groove 114 (along the y-axis).

In implementations that include laying PV modules flat and parallel to each other (such as shown in fig. 1, for example), a single reference plane may be defined for the entire array 100. However, if the array 100 comprises a tilted array (such as shown in fig. 48, for example), each PV module 102 or row of PV modules 102 along the x-axis may have its own reference plane. In an oblique row embodiment, the reference plane may be parallel to the surface of the oblique PV array in a given row, and may be located on or above the upper surface of the PV laminate 110 in that row, or on or below the lower surface of the PV laminate 110 in that row.

In the above embodiments, each support coupling is supported on the support structure 103 by fasteners into the support structure 103 or on a rail (such as rail 256 in fig. 38). In other embodiments, the leveling feet or other support couplings according to any of the above embodiments may alternatively comprise ballast trays and ballast. An example of which is shown in fig. 48. In this embodiment, the horizontal portion 442b of the cradle 442 acts as a ballast tray for supporting the ballast 458. Ballast 458 may be any of a variety of relatively heavy items such as paving material, bricks, concrete, sandbags, metal blocks, and the like. In the illustrated embodiment, ballast 458 is a block extending between and over a pair of adjacent forefoot 440 and hindfoot 450 (e.g., as shown by ballast 458a in fig. 48), although in other embodiments, ballast may be supported on a single foot or span more than two feet. The horizontal portion 442b can include upwardly extending tabs 454 for preventing the ballast 458 from sliding down the horizontal portion 442 b. The embodiments of fig. 47 and 48 may alternatively be bolted directly to the support surface 103, or to a rail (such as rail 256 described above).

Figures 49 and 50 show side and perspective views of an intermediate support coupling 460 that may be used to support a pair of tilted PV modules along the y-axis and that may engage the pair of adjacent PV modules with a coupling as described, for example, with respect to any of the embodiments of figures 37-40 above. In the embodiment shown in fig. 49 and 50, support couplings 460 may be positioned along the x-axis sides of PV modules 102 and between the module ends as shown, and interlocks 106 may be used to join a pair of modules 102 together along the x-axis.

As described above with respect to fig. 37-40, intermediate support couplings 460 may include a first upwardly extending support 466 for supporting an end of a first PV module at a first height above support structure 103, and a second upwardly extending support 468 for supporting an end of a second PV module at a second height above support structure 103. The supports 466 and 468 of different heights provide for tilting of the PV module 102 relative to the support structure 103.

In the illustrated embodiment, a central portion 462 between upwardly extending supports 466 and 468 provides a ballast tray for supporting ballast 464 as described above. The intermediate support coupling 460 may alternatively be mounted directly to the support surface 103, or to a track (such as track 256 of fig. 38) extending in the y-direction.

Fig. 51 and 52 show perspective and side views of the dual tongue leveling foot 470. The foot 470 includes a base 472, and in embodiments, the base 472 may be larger and/or bulkier than the foot 134 described above, e.g., with respect to fig. 8. The double tongue coupling 474 may be attached to the base 472 via screws 484. In an embodiment, the screw 484 may have threads only along the top portion of the screw (the portion of the screw engaged by the coupling 474). The bottom portion of the screw 484 may not be threaded, but may be secured to the base 472 via a pair of pins 486. The pin may, for example, engage within a notch (not shown) in the portion of the screw 484 within the base 472 to allow the screw 484 to rotate but not allow the screw 484 to translate relative to the base 472. Rotation of the screw 484 simultaneously prevents rotation of the dual tongue coupling 474 from translating the coupling 474 along the screw 484 to a desired height above the base 472.

The double tongue coupling 474 may include a pair of tongues 476 and 478. The tongues 476 and 478 face toward each other to engage within the grooves 114 of PV modules 102 that are adjacent to each other in the y-direction and/or the x-direction. As described above, the tongue has a thickness along the z-direction for engagement within the groove at an insertion angle and then rotated downward to a final engagement angle within the groove 114. The tongues 476 and 478 are shown as having a width that may be wider than, for example, the tongue 148 described above, but need not be greater in other embodiments. A pair of stops 480 are shown on the coupling 474 to provide a hard stop when each tongue 476, 478 is inserted into its respective groove 114. In general, the double tongue coupling 474 may provide greater strength than the leveling foot 104 and a simpler tool-less installation method.

Fig. 52A shows a perspective view of a double tongue coupling 471, which is similar to the double tongue coupling 470 of fig. 51 and 52, except that the double tongue coupling 471 in fig. 52A is formed integrally with the bracket 488 or is otherwise fixedly mounted to the bracket 488. The bracket 488 includes a base 488a and an upwardly extending portion 488 b. The double tongue coupling 474 may be formed on top of the upward extending portion 488 b. The coupling 474 in fig. 52A may be formed on top of the upwardly extending portion 488 b. Coupling 474 in fig. 52A may be structurally and operationally as described above in fig. 51 and 52. In an embodiment, the height of the double tongue coupling 471 in fig. 52A is not adjustable, such that the double tongue coupling 471 can be optimally positioned to connect to a straight surface such as the track 256 described above. However, it should be appreciated that in other embodiments, the double tongue coupling 471 may be fastened directly to a support structure (such as a roof) via a fastener or ballast.

Fig. 53 and 54 show perspective views of the stamped interlock 490. Fig. 53 and 54 are identical to each other except that fig. 54 shows an interlock 490 having a pair of interlock couplings 164, with couplings 164 omitted from fig. 53. Interlocking coupling 164 may be identical in structure and operation to interlocking coupling 164 described above, for example, with respect to fig. 15-24. The coining interlock 490 may also include an interlock plate 491 formed from, for example, a single piece of 1/8 inch steel plate. In other embodiments, interlocking plate 491 may be formed of other materials and with other thicknesses. The interlocking plate 491 may be stamped to create a plurality of tabs 492 that are bent out of the plane of the interlocking plate 491. The tabs 492 are similar in operation to the ribs 170 described above with respect to fig. 15-23. In particular, the tabs 492 are installed at an insertion angle within the groove 114 and then can engage the top bearing portion 124 and the bottom bearing portion 128 of the groove 114 when the locking position plate 491 is pivoted downwardly once the key 178 is rotated from its insertion position into its keyway 130 within the groove 114.

The interlocking plate 491 may be stamped in such a way as to define leaf springs 494 and 496 as shown at the interior open portion of the plate 491. These leaf springs 494, 496 are resiliently deflectable downward from the perspective of fig. 53 to allow insertion and fastening of the coupling 164 to the plate 491. The plate 491 may also include a lip 172 as described above, for example, with respect to fig. 15. In any of the above-described embodiments of the interlock 106 and/or the stamped interlock 490, the lip 172 may be omitted. Alternatively, for any such embodiment, a second lip (not shown) may be provided on a top portion of interlock plate 162/491 to be positioned on a top edge of frame 112 when the interlock is affixed.

Figures 55 and 56 show perspective and side views of a hybrid press-fit coupling 500 that includes a support plate 502 and press-fit legs 506. The coupling 500 may be used to mount PV modules in a reference plane and parallel to a support structure, or may be used to mount PV modules that are inclined at an angle. If tilted at an angle as in fig. 55 and 56, base 502 includes a low side 508 having a pair of couplings 294 such as described above with respect to fig. 37. One coupling element 294 is visible in fig. 53, while the other coupling element 294 has its tongue 148 engaged within the groove 114 of the PV module 102 and is not visible.

The base 502 also includes a high side defined by feet 506 that snap onto the base 502. In particular, the legs 506 include notches 516 that can snap in a press-fit relationship over tabs 510 formed in portions of the base 502. The feet 506 shown in fig. 55 and 56 may be plastic components that include structural ribs 514 for increasing the firmness of the feet 506. In other embodiments the legs 506 may be formed of other materials, such as aluminum or steel, and the ribs 514 may be omitted.

In the illustrated embodiment, the upper portion of the leg 506 includes a double-ended coupling 518 for engaging a pair of PV modules 102 adjacent to each other in the x-direction. The double-ended couplings 518 may include a pair of keys extending in opposite directions for engagement within respective grooves 114 of adjacent modules 102. Such a coupling is shown above as a double bond coupling 422 in figure 42. Alternatively, the coupling 518 may have a pair of tongues for engaging within respective grooves 114 of adjacent modules 102. Such a coupling is shown above as a double tongue coupling 470 in figures 51 and 52. The coupling 518 can also include a key and a tongue that extend away from the coupling 518 in opposite directions from one another to engage within respective grooves 114 of adjacent PV modules.

The leg 506 also includes a handle 512 for simple insertion of the coupling 518 and removal of the coupling 518. To insert the legs 506, the double-ended couplings 518 are inserted between adjacent modules 102 and rotated 90 ° downward until the notches 516 press fit over the tabs 510 and the opposite ends of the double-ended couplings 518 engage within the respective grooves 102 of adjacent PV modules.

The base 502 may be supported on the support structure 103 by fasteners passing through the base and into the support structure 103, by being mounted to rails such as rails 256, or by serving as ballast trays and placing ballast thereon.

Figures 57 and 58 illustrate front and rear perspective views of the module coupling 520. The module coupling 520 may include a plate 522 formed, for example, from 1/8 steel plate, but may be other materials and thicknesses in other embodiments. The plate 522 may be bent into right angle sections 522a and 522 b. Segment 522a may be formed to include a central opening for receiving accessory coupling 174, e.g., as described above with respect to fig. 27 and 28. Section 522a is also formed with two pairs of opposing tabs 526 bent out of the plane of section 522 a. The tab 526 has a dual function as explained below. Segment 522b is bent at a right angle relative to segment 522a and may include a hole 528 that allows the assembly to be bolted to module coupling 520 as explained below.

Figure 59 is a perspective view of PV module 102 having a pair of module couplings 520 attached thereto. In an embodiment, the section 522a has a square shape with a length and width approximately equal to the height of the frame 112. The module coupling 520 may be attached to the frame 112 in one of four orientations: a first orientation in which segment 522b is oriented perpendicular to the reference plane of module 102 and to the right of the module coupling (coupling 520a in figure 59); a second orientation in which segment 522b is oriented perpendicular to the reference plane of module 102 and to the left of the module coupling; a third orientation in which segment 522b is oriented parallel to the reference plane of module 102 and at the bottom of the module coupling (coupling 520b in figure 59); and a fourth orientation in which segment 522b is oriented parallel to the reference plane of module 102 and on top of the module coupling.

In the first and second orientations, the first pair of opposing tabs 526 are received within the grooves 114, and the second pair of opposing tabs 526 are positioned on the upper and lower edges of the frame 112. In the third and fourth orientations, the second pair of opposing tabs 526 are received within the grooves 114, and the first pair of opposing tabs 526 are positioned on the upper and lower edges of the frame 112.

As described above, accessory coupling 174 includes key 178. To attach the module coupling 520a in fig. 59, the key 178 is positioned for insertion at an insertion angle within the groove 114 while segment 522b is perpendicular to the reference plane. Key 178 is then rotated to engage module coupling 520a with frame 112 as described above. To attach the module coupling 520b of fig. 59, the key 178 is positioned for insertion at an insertion angle within the groove 114 while the segment 522b is parallel to a reference plane. Key 178 is then rotated to engage module coupling 520b with frame 112 as described above.

The tab 526 is similar in structure and operation to the tab 492 described above with respect to fig. 53 and 54. In particular, the tabs 526 mounted within the grooves 114 are inserted at an insertion angle and then can engage the top bearing portion 124 and the bottom bearing portion 128 of the grooves 114 as the module coupling 520 pivots downward once the key 178 is rotated from its insertion position into its locked position within the keyway 130 within the groove 114.

Once module coupling 170 is attached to frame 112, the various components may be attached to segment 522b via bolts in holes 528. For example, figure 59 shows assembly 530 affixed to module coupling 520a via bolts 532. Other connections may be made to any orientation of the module coupling, such as for example, for connecting the module 102 to various types of surfaces, as well as to upwardly inclined legs or ground mounted shelves.

Fig. 60 and 61 show perspective and side views of a foot stand 540 that is connected to the PV module 102 with a pivoting action similar to the interlock 106 described above. Foot stand 540 includes a base 542 having holes 546 for receiving fasteners (not shown) for affixing foot stand 540 to support structure 103. In some embodiments, the height of the foot rest 540 is not adjustable so that the foot rest 540 may be optimally positioned to connect to a straight surface such as the track 256 described above. However, it should be appreciated that in other embodiments, the foot stool 540 may be fastened directly to a support structure, such as a roof, via fasteners or ballast.

The foot stool 540 also includes an upright segment 544, the upright segment 544 including the rib 170 and interlocking coupling 164 that are the same in structure and operation as described above with respect to fig. 15-23. Coupling 164 includes a key 178 (fig. 61). The key is positioned parallel to the rib 170 and the key and rib are inserted into the groove 114 at an insertion angle. The key 178 is then rotated to pivot the foot 540 downward to engage the rib 170 and key 178 within the groove 114, thereby completing the fastening of the foot 540 to the frame 112 of the module 102.

In the above embodiment, the coupling engaged within the groove 114 generally engages the upper support portion 124 and the lower support portion 128. In other embodiments, the coupling may engage other surfaces within the groove 114. Figure 62 is a side view illustrating one such embodiment of a keyway engagement coupling 550. Coupling 550 may be formed from 1/8 inch steel plate, but in other embodiments it may be formed from other materials and other thicknesses, and need not be formed from such a piece of material. Coupling 550 includes a base 552 supported on support structure 103. The base 552 is shown folded into two layers in fig. 62, but in other embodiments it may be a single layer or more than two layers of folded material. A first upwardly extending portion 554 extends from the base 552. The length of the first upwardly extending portion 554 determines the height of the connected PV module above the support structure 103.

Coupling 550 may be, for example, two inches wide (into the page of fig. 62), but it may be wider or narrower in other embodiments. On top of the first upwardly extending portion 554, the couplings may be separated along their width dimension with a first horizontal section 556 extending in the direction of the first PV module 102a and a second horizontal section 558 extending in the direction of the first PV module 102 b. Section 556 has a second upwardly extending portion 560 and section 558 has a third upwardly extending portion 562. In an embodiment, the second portion 560 and the third portion 562 can be the same length to provide a PV array parallel to the support structure 103. In other embodiments, one of the second portion 560 and the third portion 562 may be longer than the other portion to provide a PV module that is angled as shown, for example, in fig. 48.

To assemble PV module 102a to coupling 550, PV module 102a can be inserted over second upwardly extending portion 560 at an insertion angle as described above until the top of second upwardly extending portion 560 engages within keyway 130 of frame 112 of PV module 102 a. Once the second upwardly extending portion 560 is engaged within the keyway, the PV module 102a can be rotated downward until the lower bearing portion 128 of the frame 112 engages the first horizontal segment 556 of the coupling 550. At this point, PV module 102a is secured to coupling 550.

To install PV module 102b onto coupling 550, PV module 102b may be inserted onto third upwardly extending portion 562 at an insertion angle as described above until the top of third upwardly extending portion 562 engages within keyway 130 of frame 112 of PV module 102 b. Once the third upwardly extending portion 562 is engaged within the keyway, the PV module 102b can be rotated downwardly until the lower bearing portion 128 of the frame 112 engages the second horizontal segment 558 of the coupling 550. At this point, PV module 102b is secured to coupling 550 adjacent to first PV module 102 a. Other configurations are contemplated in other embodiments, wherein the coupling engages a bearing portion other than bearing portions 124 and/or 128.

Although various terms may have their ordinary or special meanings in the art to facilitate understanding, non-limiting explanations regarding the minimum scope are provided herein below and elsewhere in the specification to facilitate understanding of the specification. Terms may be singular or plural or any tense while maintaining the same general meaning.

An arm refers to a relatively narrow device, article, feature, or portion of an article that extends, branches, or protrudes from a block or other piece; there are also very thin parts of structures, machines, instruments or apparatus that project from the main part, shaft, pivot or fulcrum. For example, the arm may be exemplified by the foot 670 of the rocker foot 652 in fig. 67 and the description thereof. As another example, spring arm 1052 of spring support 1013 may be illustrated in fig. 105 and its description. As yet another example, the spring arms 1104 of the bracket 1101 may be illustrated in fig. 110-111 and the description thereof.

Ballast refers to a heavy device, article, feature, or part of an article that provides stability or weight to cause an object to become immobilized. For example, ballast blocks 751 on the ballast pan 750 of the structural system can be exemplified in fig. 75 and the description thereof. As another example, a ballast stone 864 on tilt interlock 860 may be illustrated in fig. 86 and the description thereof.

A stent refers to a simple structure having an elongated structure (sometimes generally L or I or C in shape) and typically comprising a plate or sheet-type structure (with one dimension typically being thinner than the other dimensions in a given plate-like portion of the object). The bracket is typically a suspension member that protrudes from a structure (such as a wall or a portion of a frame) and may be designed to support a load (such as an edge) having a vertical component. A bracket may also refer to a fixture that protrudes from an arm, column, frame, etc. that may be used to hold, secure, position, or support another object. For example, a bracket for mounting a Photovoltaic (PV) module is illustrated as coupling leg 630 in fig. 63; the tilt foot 650 in fig. 65 to 68; the slide-in feet 730 and 740 in fig. 73 to 74; the tilt feet 770, 800 and 820 of fig. 77, 80 and 82 and the description thereof; spring support 1161 in fig. 116 and 117; and spring support 1340 in fig. 134-135.

A channel refers to a portion of a device, article, feature, or article, which refers to a long narrow cut, groove, notch, channel, recess, ditch, groove, rafter ditch, groove, or dimple that is typically used to guide movement or receive a corresponding male portion, ridge, or tongue. Exemplary channels 697 in the track 690 of the exemplary structural system in fig. 69-72 and the description thereof.

Connected (connected, and connecting) refers to put together or in contact or joined or fastened to form a link or association between two or more items, mechanisms, objects, things, structures, or the like. For example, a bracket connected to an interlock 651 of the PV module 102 may be shown in fig. 68 and its description. As an additional example, the bracket clip 671 attached to the rail 690 may be illustrated in fig. 70-72 and the description thereof. As yet another example, a tilt foot 650 connected to a rail 690 may be illustrated in fig. 68 and description thereof.

A connector refers to an object, article, mechanism, device, combination, feature, coupling, etc., that couples, joins, unites, or secures two or more items together. The term connector may also include devices, articles, mechanisms, apparatuses, combinations, features, couplings, etc. for holding two parts of an electrical or electronic circuit in contact. For example, connectors for connecting or coupling the plate 633 to the spring legs 631 may be exemplified in fig. 63 and the description thereof with respect to the sleeve 634.

Coupled refers to joining, linking, connecting, or mating two or more objects or items, mechanisms, objects, things, structures, etc. together. For example, the interlock 937 includes a box section 934 coupled to a clamp plate 932 and a grounding clip 933 engageable with the recess 114 in the PV module 102 as shown in fig. 93-95 and the description thereof. By way of another example, in fig. 120 and the description thereof, the tilt interlock 1200 couples adjacent PV modules 102 together.

A coupling refers to an object, article, mechanism, device, combination, feature, connection, or the like that joins, mates, or connects two things together. For example, as in fig. 63, 87, 89-92, and the description thereof, coupling leg 630 may be coupled to rail 690 and it may also couple two PV modules 102 together.

Breakaway refers to detaching, releasing, loosening, breaking free, detaching, or releasing from something that is quickly held, connected, coupled, or entangled. See below for bonding.

Engagement refers to contacting, interlocking, or engaging one or more articles, mechanisms, objects, things, structures, or the like. See detachment above. For example, the coupling legs 630 engage the rails 690, as can be exemplified in fig. 63, 69, 89-92, and the description thereof. As another example, the interlock 651 engages a groove in the PV module, as may be exemplified in fig. 66 and the description thereof.

Mounting refers to an object, article, mechanism, apparatus, combination, feature, coupling, or the like used as a support, attachment, device, or brace, or for securely securing an object or the like to a support. For example, a structural system for mounting Photovoltaic (PV) modules 102 may be exemplified by tilt interlock 1200 in fig. 120 and the description thereof.

Ground engagement as used herein refers to grounding and/or engagement. Joining refers to substantially permanently joining metal parts together to form a conductive path; such paths must have safe conduction of any false current that may be imposed on them. Grounding refers to electrically connecting to ground or joining metal objects together so that they can be connected to ground.

Length refers to the measure or range of an object, article, mechanism, device, combination, feature, coupling, etc., from end-to-end, typically along two or more dimensions of the body, which are larger or longer; which is different from the breadth or width.

Locking (locking, and locked) refers to fastening, connecting, securing, or interlocking such that a certain degree of force or movement of an engaging portion is required to unlock a locked object.

Pivoting (pivot, pivotally, and pvioting) refers to or refers to an object, item, mechanism, device, combination, feature, coupling, or the like that serves as a pivot or center point, pin, axle, or contact area on which another object, item, mechanism, device, combination, feature, coupling, or the like turns, swings, rocks, rotates, or oscillates. An exemplary pivoting mechanism, rocker foot 652, that produces a pivot fit connection to the track 690 is illustrated in fig. 70-72 and the description thereof.

Locatable refers to an object, item, mechanism, device, combination, feature, coupling, etc. that is capable of being located, placed, or configured in a particular location or in a particular manner.

PV arrays or photovoltaic arrays refer to a plurality of photovoltaic modules connected together, typically in a row-column pattern, with the module side placed in close proximity to or in contact with other modules, and sometimes including a row that is inclined relative to the underlying planar surface.

PV modules or photovoltaic modules (sometimes referred to as solar panels or photovoltaic panels) refer to encapsulated, interconnected assemblies of solar cells (also referred to as photovoltaic cells). A plurality of PV modules are typically used to form larger photovoltaic systems (referred to as PV arrays) to provide electrical power for commercial, industrial, and residential applications.

A track refers to a relatively straight, generally substantially uniformly shaped, rail, beam, truss, profile or structural member, or the like, along a length of substantially rigid material that serves as a fastener, support, barrier, or structural or mechanical member.

Rock refers to objects, items, mechanisms, devices, combinations, features, linkages, and the like that generally move back and forth or side by side along a curved path of motion. The points, lines or representations for rocking can be fixed pivot points or lines, or can be curved surfaces of one, more or varying radii. For example, the rocking bracket 652 is exemplified in fig. 67 and 70 to 72 and the description thereof. By way of another example, an arm (such as a foot 670) operable to rock a stand is illustrated in fig. 67 and its description. As yet another example, the rocking surface 6712 is illustrated in fig. 67 and 70-72.

Rotating or rotatable refers to one or more items, mechanisms, objects, things, structures, etc. that can rotate, turn, or flip around or about an axis or center.

Spring clips refer to objects, articles, mechanisms, devices, combinations, features, couplings, etc. that are typically made of a deformable material that expands to fit over (a) a shaft, rod, arm, rail, or other structure or (b) a hole, channel (see channels above), etc. that can be gripped or held under spring pressure. One common form is a press-fit spring clip in which a resilient or elastic structure is fitted or inserted through the use of force into a matching hole or channel having a slightly smaller inner diameter.

Structural systems refer to one or more objects, items, mechanisms, devices, combinations, features, chains, or the like, such as rails, brackets, racks, headers, feet, joints, connectors, and other connecting devices or structures, which may be generally placed between a support structure and a PV module; the structural system may also include a support structure. For example, the structural system, tilt interlock 1200 and its description are illustrated in fig. 122.

A support or support refers to one or more items, mechanisms, objects, things, structures, or the like that are capable of supporting a weight or other force, typically to prevent the item or the like from descending, sinking, sliding, or otherwise moving out of a normal position.

A support structure refers to a structure such as a roof, a rack, a table, a building, or a floor that can provide a base for securing PV modules to form a PV array.

Fig. 63 shows other embodiments of a mounting bracket or leg, such as a pivot leg or coupling leg, e.g., coupling leg 630. The coupling leg 630 may include a lower portion, such as a rail 690 (described in more detail with respect to fig. 69 and others), for engaging a sub-structure, such as a channel on a rail or other structure, which may be comprised of a flexible vertical arm or leg, such as a spring leg 631. The spring legs 631 may include locking tabs or protrusions, such as tab 632. The coupling leg 630 may engage the rail 690, such as by pushing the coupling leg 630 down (or in an alternative embodiment, into) onto the rail 690 (as described in more detail below with particular reference to fig. 69 and 89-92), such that the spring leg 631 may engage the angled wall 691. Due to the lead-in angle of angled wall 691, spring leg 631 engages angled wall 691 and is slidable on angled arm 691. As the spring legs 631 slide downward, the spring legs 631 may be forced apart until the tabs 632 slide past the lip 694, at which point the spring legs 631 may be able to move toward each other, causing the tabs 632 to engage against the edge 694 and the angled surface 692. The engagement between the tab 632 and the lip 694 may prevent the coupling leg 630 from pulling up or out of the track 690. In addition, the angled surfaces 692 may engage the tabs 632 such that when the spring legs 631 are pushed downward with sufficient force, the spring legs 631 are forced open until the tabs 632 contact the guide clips 693. The coupling leg 630 may also include an upper portion for engaging a groove of the PV module 102, which may be comprised of a plate or support (such as plate 633), and the plate 633 may include one or more holes or similar features for receiving a coupling device (such as coupling 444 as described further elsewhere), which may have a tongue 446 and a key 448 extending from opposite sides of the plate 633. The plate 633 and spring legs 631 may be comprised of a single piece of material, or may be separate pieces joined, such as by a hinge or other connector (such as sleeve 634), or may be attached to one another, such as by one or more rivets, pins, screws, welds, or the like. The body of the coupling 444 may engage the plate 633 such as by coining to create a tight and substantially permanent fit that cannot be easily altered, or the coupling 444 may be press fit into the plate 633 such that the coupling 444 may be rotationally displaced relative to the plate 633 as shown in fig. 64, with the dashed lines showing the final position. In the present embodiment, as will be described below, the coupling 444 may be permanently disposed in the plate 633 at an angle, such as 11 degrees from vertical (typically between 5 and 45 degrees), which corresponds to a desired final tilt angle of the PV module.

Fig. 65-68 show other support couplings in the form of angled feet 650 or similar brackets/feet (such as feet 670 including for attaching PV modules to structural systems, ballast holders, channels, rails (similar to rail 236 in fig. 38), and the like, such as rail 690). In some embodiments, foot 670 may include alternative or different embodiments of interlocks (similar to interlocks 106 in fig. 14), such as interlocks 651 and support feet, brackets, and the like, such as rocker foot 652. The interlock 651 may be attached to the rocker 652, such as by one or more rivets, pins, screws, welds, or the like (such as rivet 653). In other embodiments, interlock 651 and foot 670 are different portions of a single piece of material, and thus rivets are not required in such embodiments. In some embodiments, the foot 670 has a clip 671 integrated or attached as shown in fig. 65.

Referring now to fig. 66, the interlock 651 provides an alternative means, including an apparatus and method of engaging a groove or the like in a PV module (similar to the groove 114 in the PV module 102 in fig. 3) (as shown in more detail below, particularly with reference to fig. 66). In other embodiments, the interlock 651 may surround the PV module frame such as shown in fig. 29-36. Referring now particularly to fig. 66, interlock 651 may comprise a plate, bracket, or the like (such as interlock plate 660 made of bent steel or other suitable material, such as aluminum or other metal or plastic) that features to engage and pivotally mate to groove 114 in a manner similar to tongue 148 (see, e.g., fig. 11-13A), tongue 476 (see, e.g., fig. 51), and rib 170 (see, e.g., fig. 17-23), except that the exact shape of the pivotally mating portion may be slightly altered. The pivot mating portion of interlock 651 may include a flange, lip, tab, wall, or the like, such as angled flange 661. Interlock 651 may be made from sheet material having a thickness of, for example, 2.5mm (typically between 1.0mm and 5.0 mm). Angled flanges 661 may be bent at an angle (such as 75 degrees, typically between 61 degrees and 89 degrees), which may produce a sharp cutting edge, teeth, etc., such as cutting edge 663, on each (or at least many and preferably most) of angled flanges 661. As will be discussed in more detail below with reference to fig. 88, the angled flange 661 can include a height that enables at least partial insertion into the groove 114 when the PV module 102 is positioned at an insertion angle relative to the interlock 651. In this embodiment, because the final plane of the PV module 102 may be tilted at an array tilt angle (e.g., from 3 degrees to 50 degrees) relative to the roof surface, this insertion angle may be equal to the angle required to allow the angled flange 661 to be at least partially inserted into the groove 114 (on a pair of adjacent PV modules 102) plus the array tilt angle. Subsequent rotation of the PV module 102 from the insertion angle to the array tilt angle may cause a pivot-fit action between the upper and lower portions of the angled flange 661 and the offset bearing surfaces 124, 128 within the groove 114 as described with respect to other implementations above. In some embodiments, rotation to the array tilt angle may also cause the cutting edge 663 to cut a portion of the frame 112 and/or deform a portion of the frame 112 for taking up tolerances and/or providing a ground engaging connection between the interlock 651 and the frame 112. In the present embodiment, flange 662 provides rigidity to interlock 651, but it will be appreciated that flange 662 may be omitted, such as if greater rigidity is not required. As shown more clearly in fig. 66, the vertical wall 666 may include a guide surface or edge (such as guide 668) and a gap, void, or cutout, such as gap 667. The clips 668 can be used to engage slots or other features within a groove of the PV module frame or on a surface of the PV module frame. The gap 667 is shown here as having a tab, projection, or extension (such as tab 665 that at least partially retains a portion of the rocker foot 652), although alternative variations are expressly contemplated. In this embodiment, the attachment holes 664 can be used to attach the interlock 651 to other supporting frames or brackets, such as the rocker feet 652, as shown in fig. 65. It should be apparent that interlock 651 can be attached to many embodiments of the structural system and/or foot stand and can be attached by many different means, such as one or more rivets, screws, pins, bolts and nuts, welds, clips, and the like.

Referring now to fig. 67, the rocker foot 652 may be comprised of a foot, support, or the like (such as foot 670) and a retainer, spring, clip, or the like (such as clip 671) that may be made of a resilient material. In some embodiments, the foot 670 may perform the function of a lever arm that rocks the rocker foot 652 into engagement. A more detailed description of the structure, use, purpose, and function of the rocker foot 652 will be described below with particular reference to fig. 70-72. The clip 671 may be attached to the foot 670, such as by one or more rivets, pins, screws, welds, or the like (such as rivet 672). The clip 671 may be made of a resilient or spring material, such as spring steel, plastic, rubber, or other resilient material, and may include an angled ramp or wall, such as angled wall 6715. The clip 671 may also include a support surface or stop surface (such as stop surface 6713 and stop tab 6714).

Referring to fig. 67, the foot 670 may be made of steel plate or other suitable metal, plastic or similar material having a thickness such as 4mm (typically between 2.0mm and 8.0 mm). The foot 670 may include a vertical support section (comprised of an angled flange or tab, such as angled tab 673), a vertical riser or wall (such as riser 674) that may or may not include a reinforced wall, tab, or flange, such as flange 675. The angled tabs 673 can bend at an angle (such as 75 degrees, typically between 61 and 89 degrees) which produces a metal deformed edge, a sharp cutting edge, teeth, and the like, such as the deformed edge 676. In other embodiments, the deforming edge 676 may be formed by means other than the angled tab 673, such as by attaching a separate deforming member, cutting tooth, sharp object, etc. to the rocker foot 652. The deforming edges 676 are collectively referred to as an engagement portion 6716 of the rocker foot 652. In other embodiments, the engagement portion 6716 can include one or a number of deformed edges 676. The bend that creates the angled tab 673 may also create a pivot point, pivot line, rocking surface, or pivot surface, such as the rocking surface 6712. As will be described further below, rocking surface 6712 and deforming edge 676 may be used to actively engage a support surface, ballast retainer, track, or channel (such as track 690). The riser 674 extends to a desired height, and may terminate at additional angled flanges or tabs, such as angled tab 677. Angled tabs 677 may include a plurality of attachment holes, such as hole 678, for attaching additional components, such as interlock 651, such as by rivet 653 in fig. 63. The angled tabs 677 extend to an edge, terminal end, or surface (such as a stop surface 679), the purpose of which is described further below, particularly with reference to fig. 68. As will be discussed in more detail below, the feet 670 may include vertical walls, tabs, flanges, etc. (such as tab 6710) and wings, tabs, etc. (such as wing 6711).

Referring now to fig. 68, an interlock 651 is shown engaging or connecting a recess 114 in a PV module, such as PV module 102. The angled flange 661 may be bent such that the distance from the cutting edge 663 to the bottom of the interlock plate 660 is greater than the distance between the bearing surfaces 124 and 128, as shown by distance "n" in fig. 4. It should be appreciated that interlock 651 may be made of alternative thicknesses and materials, and angled flange 661 may be bent at an angle other than 75 degrees, but typically between 61 and 89 degrees, while maintaining a distance between cutting edge 663 and the bottom of interlock plate 660 greater than "n", as shown in fig. 4. The blocking surface 679 may prevent the interlock 651 from entering too far into the recess 114. The lead 668 as shown projects above the cutting edge 663 into the upper recess 130a (see fig. 4) of the groove 114. Guide clip 668 can be used to prevent interlock 651 from being pulled out of recess 114 and create a leveling point to assist in insertion of interlock 651 into recess 114.

Fig. 69 shows a perspective view of the rail 690. The track 690 may include one or more of a number of features that engage a support bracket, foot, or the like (such as foot 670) and other embodiments as will be described below. In this embodiment, the track 690 may include a channel 697 extending partially or substantially the entire length of the track 690 and inwardly angled walls or surfaces (such as angled walls 691). The rails 690 may also include downwardly angled surfaces, such as angled surfaces 692. Other features may include short vertical walls, blocking surfaces or guides (such as guide 693) and horizontal walls, blocking surfaces or lips, such as lip 694. The track 690 may also include a horizontal wall or support surface, such as support surface 695. Other features may include a lower facing surface or a tab, such as a blocking lip 696.

Referring now to fig. 70-72, the mounting of the rocker foot 652 into the track 690 is described. Fig. 70 shows the rocker foot 652 tilted at an insertion angle such that the tab 6710 may be located on the rail 690 and the rocker surface 6712 may be approximately flush with the support surface 695. It is expressly intended that the insertion angle may be from about 1 degree to 45 degrees, but is typically between 20 degrees and 35 degrees, relative to the final angle as discussed below. As shown in fig. 71, the rocker foot 652 can be inserted in the direction shown by the arrow on fig. 70 to a position inside the channel 697 of the track 690 so that a substantial portion, even a majority, or even the entire length of the rocker foot 652 can be located inside the track. A downward force may then be applied to the top of the tab 6710 by, for example, the foot of the installer as indicated by the arrow on fig. 71. The downward force causes the rocker foot 652 to pivot or rock about the rocking surface 6712. With the tab 6710 pressed downward, the angled walls 6715 of the clip 671 may be forced together until the rocker foot 652 rocks to a final angle where the blocking surface 6713 is below the blocking lip 696 on the rail 690. As the rocker foot approaches the final angle, the engagement portion 6716 may begin to engage the stop lip 696. This engagement action may cause the deformation edge 676 to deform, pierce, or cut the blocking lip 696, creating a more robust mechanical and (in some embodiments) electrical ground engagement connection between the rocker foot 652 and a structural system, such as the rail 690. Since the clip 671 may be made of an elastic or spring material, the angled wall 6715 may open to approximately its original angle, engaging the stop surface 6713 against the stop lip 696 to effectively connect the clip 671 to the rail 690 and prevent rotation in that direction from the final angle back to the insertion angle. Those skilled in the art will recognize that the rocker foot 652 is thus connected to the rail 690 by a pivot-fit action, such that the offset bearing points (deforming edge 676 and rocker surface 6712) at each end of the angled tab 673 are rocked or pivoted by a lever arm, such as foot 670, until a tight fit is achieved, and then the fit is maintained by engaging the spring clip 671. The blocking tab 6714 may prevent the clip 671 from opening too deeply and may also provide a way to remove the rocker foot 652 from the rail 690. To remove the rocker foot 652, the blocking tabs 6714 may be squeezed together until the blocking surface 6713 disengages the blocking lip 696, allowing the rocker foot 652 to pivot about the rocker surface 6712 and be removed by approximately reversing the installation order described above. In some embodiments, the rocking surface 6712 may be a fixed pivot point or line, while in still other embodiments, the rocking surface 6712 may be a curved surface of one, more, or varying radius that allows the rocking foot 652 to substantially rock, such as by rocking along the rocking surface 6712, as the rocking foot 652 rotates from the insertion angle to the final angle.

Referring now again to fig. 68, it also shows how forces may act on the foot 670 in windy environments. As air flows through a PV module, such as PV module 102, a generally upward force normal to the surface of PV module 102 (as shown by the arrows and designated force F) may be generated and transferred at least partially to feet 670 through bearing surfaces 128. Thus, force A at bearing surface 128 as shown approximately represents the portion of force F that is present at foot 670. Force a creates a moment about the pivotal portion of foot 670, as indicated at point P in the rocking surface 6712. Since the clip 671 can engage the blocking lip 696 on the rail 690 (such as shown in fig. 72), a reaction force (as shown by the arrow and designated force C) is applied by the rail 690 to the clip 671. Those skilled in the art will recognize that the magnitude of force C is approximately proportional to force a, the ratio being the ratio of the distances D1 and D2 between pivot point P and the point at which each of the forces is applied (assuming for this figure that the angle of force a relative to the vertical may be relatively small and does not significantly alter the results of this analysis). Because force a (as shown) is applied at bearing surface 128 and distance D1 from where force a is applied at point P is extremely small compared to distance D2 (e.g., D2 is 10 times greater than distance D1), the magnitude of force C may be much less than force a (e.g., about 10 times less than force a). Even if the PV module 102 is presented with wind loads, the ability of the angled foot 650 to significantly reduce the force required at the clip 671 provides significant benefits including: reducing the material size, thickness, and/or strength of the clip 671 (thereby reducing the cost of the ramp 650 compared to previously known systems); the need for a tool to connect the angled foot 650 to the rail 690 may be eliminated because this clip is small enough and flexible to allow the above-described rocking motion to be actuated by hand or foot; and simplifies the installation procedure because the foot 670 can act as a lever arm with significant mechanical advantage of having the deforming edge 676 solid-state engage the lip 696, thereby additionally allowing for ground engagement at the deformed region.

It is recognized that the brackets, mounting feet or feet (such as the angled feet 650) may be configured in a variety of ways, but generally include a lower portion for engaging a substructure (such as rails 690, rails, beams, girders, rafters, ballast pans or trays, roof seams or surfaces such as substantially flat structural systems or inclines as shown in fig. 1) and an upper portion for engaging the PV module (module 102) (also shown in fig. 1). Fig. 74 shows an alternative embodiment of a stand or foot, such as a slide-in foot 740. Slide-in foot 740 is similar to tilt foot 650 except that slide-in foot 740 is connected to the structural system, such as by or via a squeeze slide action rather than a shaking action like tilt foot 650. The slide-in foot 740 includes a lower foot 742 for engaging a rail or channel (such as rail 690) and an upper interlock 741 for engaging a groove (such as groove 114) in the PV module. Interlock 741 is attached to foot 742 using one or more rivets, pin screws, welds, or the like, such as screws 745 (only one shown for clarity). The foot 742 may include a plurality of edges or blocking surfaces, such as blocking surface 743. Interlock 741 may include a protruding section or tongue, such as tongue 746. The tongue 746 may engage the groove 114 in a manner similar to the tongue 148 shown in fig. 11. The interlock 741 may have a length suitable for engaging one or more PV modules to couple them together. The slide-in foot 740 may be inserted into the track 690 by squeezing the feet 747 and 748 so that the blocking surface may slide freely between the blocking lip 696 and the support surface 695. The release feet 747 and 748 can then drive the one or more blocking surfaces 743 into the blocking lip 696 to connect the slide-in foot 740 to substantially any desired position along the length of the track 690.

Fig. 73 illustrates other embodiments of a mounting foot, bracket, or support foot (such as slide-in foot 730) similar to slide-in foot 740 previously described. As shown in fig. 76, the slide-in foot 730 is adapted to slide into the track 690 without a squeezing or retracting action as with the slide-in foot 740. Conversely, the slide-in foot 730 slides into the rail 690 to a desired position along the length of the rail 690, and then a bolt, screw, or other threaded fastening mechanism (as shown) may be inserted or threaded through the hole 734 to drive the blocking surface 733 into the blocking lip 696 and secure the slide-in foot 730 to the rail 690. The slide-in foot 730 may include an interlock 731 similar to interlock 741. Slide-in foot 730 may provide a stronger or lower cost alternative to slide-in foot 740. Combinations of the two forms of slide-in feet (730 and 740) and other methods and devices as would occur to those of skill in the art may also be used.

Fig. 77 shows another embodiment of a mounting foot, bracket or support foot (such as angled foot 770) similar to angled foot 650. The angled leg 770 may be comprised of an upper interlock 771 similar to interlock 741 used to engage a groove in a PV module, such as groove 114. The angled foot 770 may also be comprised of a base (such as foot 772) that may be similar in form and function to the rocker foot 652 mentioned and described above, but the functions of the foot 670 and clip 671 are combined in one piece of material. In the embodiment shown in fig. 77, the foot 772 includes a tab or flange (such as tab 773) or cutting edge, such as cutting edge 774, bent at this angle to create an acute angle. Cutting edge 774 may perform the same or similar function to deformed edge 676 on foot 650. The foot 772 may also include a set of curved flanges or tabs, such as flange 775. Since the foot 772 can be made of a resilient or spring material (steel, aluminum, plastic, etc.), the flange 775 can perform the same function as the clip 671.

Fig. 80 illustrates another embodiment of a mounting foot, bracket or support foot (such as foot 800) similar to foot 650 previously described. The tilt foot 800 may be comprised of a bottom foot 801 (such as the track 690 previously described with particular reference to fig. 69-72) for engaging a structural system. Bevel foot 800 may also include an upper interlock 802 similar to interlock 651 previously described, except that interlock 802 is shown to include a flange, gusset, or tab (such as gusset 803) that may be formed in or on foot rest 801 or attached to foot rest 801, such as by one or more rivets (as shown), pins, screws, welds, or the like, to increase the carrying capacity of bevel foot 800. Those skilled in the art will recognize many other ways, articles, or features that may increase the carrying capacity of the bevel foot 800, such as, for example, using stronger materials, using thicker materials, or adding formed ribs, gussets, etc.; all such other manners, articles, or features are expressly contemplated herein.

Fig. 81 illustrates other embodiments of a mounting foot, bracket, or support foot (such as angled foot 810) similar to angled foot 650 previously described. Angled leg 810 is similar to angled leg 650 except that angled leg 810 is made from a single piece of starting or raw material, thereby reducing manufacturing costs.

Fig. 82 illustrates other embodiments of a mounting foot, bracket, or support foot (such as angled foot 820) similar to angled foot 650 previously described. The angled leg 820 is similar to the angled leg 650 except that the angled leg 820 provides an alternative means of engaging the groove 114 in the PV module frame. The angled leg 820 may include an engagement portion 821 having an upper engagement portion 822 and a lower engagement portion 823 rather than being engaged primarily via or by insertion into the groove 114. The angled leg 820 may be connected to the PV module 102 via or by at least partially inserting the upper engagement portion 822 into the recess 114 and contacting the lower engagement portion 823 with the bottom surface 824 of the PV module 102. In some embodiments, the upper engagement portion 822 and the lower engagement portion 823 serve as offset bearing points as previously shown in fig. 30A and 39. The oblique foot may also include a foot 825 that operates in a manner similar to foot 670, as described above. The tilt foot 820 may also have placed thereon one or more ballast or weights as shown to hold the tilt foot 820 in place, as more fully described elsewhere, such as with respect to fig. 75.

Fig. 83 illustrates other embodiments of a mounting foot, bracket, or support foot (such as angled foot 830) similar to angled foot 650 previously described. Angled foot 830 is similar to angled foot 650 except that angled foot 830 provides an alternative means of engaging the frame of the PV module. The ramp 830 may include a surrounding engagement portion 831 having an upper engagement portion 832 and a lower engagement portion 833, rather than engaging primarily, such as by or via insertion into the recess 114 (as is done with the ramp 820 in fig. 82). The angled foot 830 may be connected to the PV module 102, such as by or via a wrap-around pivot-fit action as described in other embodiments above (such as shown in fig. 39). In some embodiments, the upper engagement portion 832 and the lower engagement portion 833 serve as the offset bearing point previously shown in fig. 30A and 39. The angled feet may also include feet 835 that function in a similar manner to feet 670 described above. As described more fully elsewhere, such as with respect to fig. 75, the tilt foot 830 may also have placed thereon one or more ballast or weights as shown to hold the tilt foot 830 in place.

Fig. 75 shows an exploded view of a slide-in foot 740 connected to a structural system that may include a track 690, a tray, or a container, such as a ballast pan 750, and a weight, stone, or block, such as a ballast block 751. In some embodiments, the structural system as shown in fig. 75-76 may also include a support structure, such as a roof or portion thereof (not shown in fig. 75-76, but generally below and coplanar with the bottom of the track 690). The ballast disk 750 may have one or more tabs or flanges (such as tab 752), which may have a width greater than the opening in the track 690 such that the tab 752 will cut the track 690. Since the ballast pan 750 may be made of a conductive sheet metal material (such as steel), the cutting action of the tab 752 into the rail 690 may create an electrical engagement, such as a ground engagement. The ballast blocks 751 can be placed at least partially on or within/inside the ballast pan 750, providing a downward retention force on the rails 690 with a force approximately equal to the weight of the ballast pan 750 and ballast blocks 751. Fig. 76 shows a slide-in foot 740 and rail 690 engaged as described above. As will be described more fully below with particular reference to fig. 96, the ballast pan 750 may also include features for engaging diffuser support couplings and/or diffusers. The features may include one or more holes, notches, or slots, such as slot 753. In other embodiments, the track 690 is secured to a support structure, such as a roof, such as by or via fasteners other than and/or in addition to ballast weights as are known in the art.

Additional embodiments of tilt interlocks (see, e.g., the interlocks shown in fig. 37-38) are shown in fig. 84-86. In fig. 84, a structural system is shown that includes tilt interlocks (such as tilt interlock 840) that can interlock two, three, or four PV modules 102 together by connecting PV modules 102 to tilt interlock 840 via couplings 841 and 842. Coupling members 841 and 842 may operate similar to coupling members 290 and 294 except that coupling members 841 and 842 may be located in a different number of positions relative to upright portions 844 and 845. Thus, one or more of the couplings 841 or 842 (or other forms of couplings) may be located on each of the short and high upright portions 845, 844 portions of the interlock 840 (or the interlock 850), and furthermore, zero or more of another form of coupling, such as the coupling 842 or 841, may also be located on either upright portion 844 or 845 or both upright portions 844, 845. The uprights 844, 845 may or may not be substantially parallel, and in some embodiments may be connected to one or more of the various structural systems (such as rails, beams, stringers), such as by or via holes 846, which may include any suitable connection means, such as bolts, rivets, etc. (not shown), or directly to a support structure, such as a roof. Coupling 841 may include a key for connection to groove 114 as described elsewhere. The coupling 842 may include a tongue 848 for connection to the groove 114 as also described elsewhere. Fig. 85 shows another embodiment of a tilt interlock, such as tilt interlock 850, which may be similar to tilt interlock 840, except that the two coupling members 851, 852 are shown on the short upright portion 845. Coupling 851 is similar to coupling 841 and coupling 852 is similar to coupling 842 except that couplings 851 and 841 are located in different positions. Further, as mentioned above, any combination or permutation of one or more couplings (such as 841, 842, 851, and 852 or other forms) may be located on either upright 844 or 845 or both upright 844, 845.

Fig. 86 illustrates a side cross-sectional view of a structural system including a tilt interlock (such as tilt interlock 860) that may include a ballast stone block 864 for resisting a lifting load on PV module 102. The interlocking coupling 860 may also include tongue portions 862, 863 for connecting to the groove 114 in the PV module 102. Similar to the pivot-fit connections described above, tongue portions 862, 863 may be pivotally fit connected to PV module 102.

Fig. 87-92 illustrate some of the assembly steps required to construct an array of tilted PV modules on a flat surface using a structural system as described in the embodiment of fig. 87-92 and as described similarly to fig. 37-50. The coupling legs 630 may be adapted to rotationally engage grooves in a frame of a PV module (such as PV module 102) as previously described with particular reference to fig. 44-48. In this embodiment, the coupling legs 630 are adapted to slide into the PV module groove 114 when the PV module groove 114 is held at an angle of approximately 11 ° (typically between 3 and 30 degrees) relative to the plane of the PV module 102. The coupling leg 630 may then be rotated approximately 90 ° (typically between 75 degrees and 105 degrees) to connect the coupling leg 630 to the PV module 102. Fig. 87 shows a side view of the first PV module 102 held at an insertion angle as described above in a given row such that the coupling legs 630 engage as described above. The angled foot 650 is shown in fig. 87 as having been slid into the track 690 and locked into place as previously described. The ballast disk 750 is also shown engaging the rail 690 as previously described in fig. 75. PV module 102 can be angled as described above to be inserted at an angle to at least partially engage interlock 651 on ramp 650 having recess 114. Fig. 88-89 illustrate the PV module 102 after the PV module 102 is at least partially engaged with the interlock 651 as described above. The PV module 102 can now pivot and rotate downward on the interlock 651 until the coupling legs 630 engage the rails 690 as shown in fig. 89, and the interlock 651 pivotally engages the offset bearing portions 124, 128 of the frame 112. Fig. 90 shows the final position of the coupling leg 630 relative to the PV module 102. Fig. 91 shows the second PV module 102 in a position substantially coplanar with the first PV module 102, aligned such that the second coupling leg 630 can be inserted between the two PV module edges, wherein the coupling 444 is oriented such that the key 448 can engage in the groove of one PV module and the tongue 446 can engage in the groove of the other PV module, thereby coupling the two PV modules 102 together. Fig. 92 shows how the coupling leg 630 can then be rotated to the position as previously shown in fig. 89 and then engage the track 690 as shown in fig. 90. Since the coupling leg 630 may be constructed of an electrically conductive material and the coupling member 444 may be electrically joined to the PV module 102 as described above, those skilled in the art will appreciate that the PV module 102 may be electrically connected to the rail 690 through the coupling member 444 and the coupling leg 630. While the interlock 651 is almost concealed by the module 102 in fig. 91, those skilled in the art will recognize that the first angled flange 661 on the interlock 651 engages the first PV module 102 as shown in fig. 88 and the second angled flange 661 on the interlock 651 generally engages the second PV module 102 as shown in fig. 91.

Fig. 93-95 present other embodiments of interlocks, ballast pan connectors or couplings with integral interlocks, such as diffuser support couplings 930. The diffuser support coupling 930 may comprise a curved bracket or plate (such as the diffuser support coupling 931) formed from a rigid material such as steel to create a rectangular cross-section or a bracket such as the box-shaped cross-section 934. A bracket or plate, such as guide plate 932, may be attached, such as by one or more rivets, pins, screws, welds, or the like, to the top of box section 934. The guide plate 932 may have a curved flange or lip, such as guide clamp 935. One or more clips or brackets, such as ground clip 933, may be affixed to the bottom of box-like section 934, such as by one or more rivets, pins, screws, welds, or the like. Ground clip 933 can be formed of spring steel or the like with two flanges angled downward to create cutting edge 936 in a manner similar to cutting edge 663 on interlock 651 in fig. 66. The box-like section 934, which couples with the guide plate 932 and the ground clip 933, forms an interlock 937, which interlock 937 can engage a recess in a PV module, such as recess 114 in PV module 102, via a pivot-fit action similar to the tongue 746 in fig. 74 and other interlocks and/or tongues described above. Since the box section 934, the guide clamp plate 932 and the ground clip 933 may be made of steel plate and permanently connected, such as by one or more rivets, screws, pins, solder joints, etc., the assembly may then be electrically connected, which may form a ground connection. When the interlocks 937 are inserted and the interlocks 937 engage the grooves 114, the cutting edge 936 can deform or cut the bearing surface 128 into the bearing surface 128, thereby creating an electrical contact between the PV module 102 and the diffuser support coupling 930. The diffuser support coupling 931 may also include features for a wind diffuser as will be shown below with particular reference to fig. 98 and for engaging a ballast disk (such as ballast disk 750) as will be described in more detail below with particular reference to fig. 96. The features may include one or more holes, slots or notches (such as slot 938) and/or one or more hook-like flanges or tabs (such as hook-like tab 939). In other embodiments, the diffuser support coupling does not include the diffuser support bracket 931. In still other embodiments, the interlock 937 does not include other elements shown in the diffuser support couplings, and thus serves solely as an interlock capable of coupling two adjacent PV modules together via a pivot-fit action.

Fig. 96 is a side view of a PV module mounted to a structural system and showing how the diffuser support couplings 930 may engage grooves in the PV module, such as the grooves 114 in the PV module 102. First, the diffuser support couplings 930 may be inserted into the grooves 114 of the PV module 102 at an angle similar to the insertion angle. The diffuser support coupling 930 may then be rotated downward such that the guide plate 932 contacts the bearing surface 124 and the cutting edge 936 contacts the bearing surface 128. Next, the ballast pan 750 may be positioned below the diffuser support coupling 930 such that the hook tabs 939 may be inserted into the slots 753. Tabs 752 on the ballast disk 750 may then be pushed into the rails 690, cutting into the rails 690 to make electrical contact. Since the ballast disk 750 and diffuser support couplings 930 may be made of electrically conductive materials, electrical connections such as ground paths are made from the PV module 102 through the diffuser support couplings 930 (as described above), through the ballast disk 750, and through the rails 690.

Fig. 97 shows a dual module PV array including PV modules 102 with an additional three diagonals 650 connected to rails 690. Those skilled in the art will recognize that the second row of PV modules 102 may be installed by repeating the above steps in a manner similar to the row shown in fig. 97 to connect the PV modules 102 to the rail 690 with the angled feet 650 and the coupling feet 630. In some embodiments, the rails 690 may extend primarily between rows with the first and last rails being pushed against under the PV module 102 to prevent them from protruding too far (as shown as the rightmost rail 690 in fig. 97 being pushed under the PV module 102). In other embodiments, the track 690 may be cut longer to connect multiple rows together. Those skilled in the art will appreciate that PV module 102 may be connected to track 690 by angled feet 650, coupling legs 630, and a series of components including diffuser support couplings 930 and ballast pan 750. Thus, as shown in fig. 97, electrical connections may also be established between rows of PV modules 102 when additional angled feet 650 may be installed in the rails 690. Further, it has been shown above that electrical connections can be established between PV modules 102 in a row by cutting edge 663 on interlock 651, coupling 444 on coupling leg 630, and cutting edge 936 on ground clip 933.

Those skilled in the art will also appreciate the benefits provided by the addition of a wind deflector, shroud, or wind diffuser, such as wind diffuser 980 as shown in fig. 98. The benefits include a significant reduction in the upward force generated by air flowing from behind and below the array of PV modules. The wind diffuser 980 may direct the airflow through the PV module, reducing upward forces, which allows for the use of fewer ballast blocks and possibly less robust and less expensive structural components to support and mount the PV array. The wind diffuser 980 may be made of a curved plate or molded material (such as metal, plastic, concrete, etc.) in a generally rectangular shape. The wind diffuser 980 may be mounted to the PV array by resting on the diffuser support couplings 930 and engaging the diffuser support couplings 930. The wind diffuser 980 may be attached to the diffuser support coupling 930, such as by one or more pins, clips, rivets, screws, welds, and so forth, not shown. In other embodiments, the wind diffuser 980 may be connected to the PV module trough 114 and structural systems (such as rails 690), and/or directly to a support structure, such as a roof, or the like.

Those skilled in the art will recognize that the support system including the combination of angled feet 650, rails 690, coupling feet 630, ballast blocks 751 and air deflectors 980 may be reproduced between adjacent PV modules and at the row edges of PV modules in a larger array of PV modules 102 in a similar fashion as shown in fig. 98. And the exact number of ballast blocks within a larger array of PV modules 102 may vary depending on the local load on a particular PV module 102 within the array. For example, in some embodiments, the wind load may be higher than near the edges of the array of PV modules 102, and thus the ballast blocks 751 located near the edges may be more than the ballast blocks 751 in the middle of the array. In other embodiments, the ballast blocks 751 may be replaced by screws, brackets, clamps, or other means of mechanically connecting the rails 690 to a structural system or directly to a roof or other support structure in some or all locations within a larger array of PV modules 102.

Fig. 99-100 show perspective views of an array of PV modules supported in an inclined orientation by an alternative embodiment of a structural system comprising a block, base, or support, such as support base 990. It is expressly contemplated that support base 990 may be constructed of concrete, metal, plastic, etc., and provide sufficient weight to reduce or, in some embodiments, eliminate the need for additional fasteners to resist lifting or lateral loads. The support base 990 may include a lower surface 991 and an upper surface 992 to which additional PV module engagement assemblies may be attached, such as by one or more screws, pins, spring clips, rivets, welds, or the like. In other embodiments, PV module engagement assemblies, such as leveling feet, interlocks, couplings, and the like, may be connected to the support base via a pivot fit or press fit engagement. In this embodiment, the lower surface 991 includes a coupling member 993 similar to the coupling member 474 in fig. 51. The upper surface 992 provides a raised surface on which additional structural systems (such as leveling feet 994 similar to leveling feet 470 in fig. 51) are mounted. It should be appreciated that both the lower surface 991 and the upper surface 992 may have a variety of PV module engagement assemblies, including but not limited to a coupling 993 and a leveling foot 94. By way of non-limiting example, lower surface 991 or upper surface 992 may be adapted to connect to interlock 651 or interlock 741. The support base 990 also includes a plurality of attachment points or anchors (such as threaded studs 995) to which deflectors, shrouds, or plates (such as the wind diffuser 1000 shown in fig. 100) are attached. In some embodiments, the array of PV modules 102 may include a support base similar to support base 990, except having different weights depending on local wind and or snow-loaded conditions within the array of PV modules 102.

Fig. 101-105 illustrate other embodiments of structural systems for supporting inclined PV modules, such as support system 1010. The support system 1010 may include: a support base 1011 similar to support base 990 (except that it includes one or more removable ballast weights), as described above, on which support base 1011 is mounted a PV module engagement assembly (such as interlock 1012); and a spring support or clip (such as spring support 1013). The interlock 1012 may function similar to the interlock 651 except it may include a separation tab 1030 for aligning and/or separating two adjacent PV modules 102. The support base 1011 may also include a portion for containing ballast, such as a ballast pan 1016, which may be integral with the support base 1011 or may be attached, such as by one or more rivets, pins, screws, welds, spring clips, or the like. Fig. 101 also shows an optional deflector, shroud or plate, such as a wind diffuser 1014. In some embodiments, there is no wind diffuser 1014. The wind diffuser 1014 differs from the previous embodiment in that: the upper portion includes features for engaging a PV module frame groove, a tongue 1017 similar to tongue 746 on interlock 741, and other pivot mating features as described herein. The lower portion of the wind diffuser 1014 may be attached to the support base 1011 using one or more screws, pins, rivets, welds, clips, or the like, such as spring clips 1015. The one or more ballast trays 1016 are adapted to include one or more ballast blocks, such as ballast blocks 751 as shown in fig. 75. Those skilled in the art will recognize that the support system 1010 may be reproduced in a similar fashion as shown between adjacent PV modules and at the row edges of PV modules in a larger array of PV modules 102. And the exact number of ballast blocks may vary for each support system 1010 within a larger array of PV modules 102.

Referring now to fig. 105, a spring bracket 1013 suggests an alternative apparatus and method for adapting an assembly to engage a recess in a PV module, such as recess 114 in PV module 102. The spring support 1013 may be made of a steel plate or a plastic plate or the like and may have a thickness of, for example, 3mm (typically between 1mm to 6mm if a steel plate). Base 1050, which includes lower portion 1054 (shown in phantom because it is below support base 1011), may pivotally engage support base 1011. The spring support 1013 may also include a flange, tab, or tab, such as tab 1051, adapted to fit loosely within the groove 114 between the bearing surfaces 124 and 128 as shown in fig. 4, 5, 6A, and 6B. The spring support 1013 may also comprise a long support, lever or arm, such as a spring arm 1052 adapted to at least partially flex when pressed by a hand or tool. The ends of the spring arms 1052 may be bent such that a flange or tab, such as the hook tab 1053, is adapted to fit in the groove 114 in order to provide a retention force that maintains the spring mount and pivot-fit connection between the offset bearing point bearing surface 128 and the underside of the support base 1011. For installation, the spring bracket 1013 may be positioned such that the hook tab 1053 is slightly above the top surface of the PV module 102 as shown, and the lower portion 1054 is below the bottom side of the support base 1011. The spring support 1013 is then moved laterally toward the PV module 102 until the tab 1051 is at least partially inside the groove 114 and the spring arm 1052 is approximately parallel to the length of the groove 114. In some embodiments, a second PV module 102 can be placed adjacent to and coplanar with the PV module 102 (the second module 102 is not shown in fig. 105) such that one of the tabs 1051 is at least partially inserted into the groove 114 on the second PV module 102. The spring arm 1052 can then be pressed downward toward the PV module 102 with an external mounting force, causing the spring support 1013 to rotate at a pivot connection point (such as pivot portion 1055) until one or more of the tabs 1051 contact the bearing surface 128 in the PV module 102 or an adjacent module 102. Once the tab 1051 contacts the bearing surface 128, the spring arm 1052 deflects until the hook tab 1053 is below the bearing surface 124, at which time the hook tab 1053 enters the channel 114. When the external force on the spring arm 1052 is removed, the hook tab 1053 securely contacts the bearing surface 124, the downward force on the bearing surface 128 is maintained by the tab 1051, and an upward force is applied to the support base 1011 underside. In some embodiments, the tab 1051 can deform portions of the groove 114, thereby creating a ground engagement therebetween. In other embodiments, the lower portion 1054 can deform a portion of the bottom side of the support base 1011, creating a ground engagement that always couples the groove 114 further to the support base 1011. In still other embodiments, some or all of the parts may be made of plastic, thereby eliminating the need for grounding.

Fig. 106-107 show other embodiments of wind diffusers, deflectors, or shrouds (such as wind diffuser 1060). The wind diffuser 1060 may be adapted using holes or slots (such as the hole 1061) adapted to engage a coupling or attachment (such as the diffuser coupling 1062) that may be functionally equivalent to the accessory coupling 198 as described above with particular reference to fig. 27 and 28. For example, the diffuser coupling 1062 may include a key 1064 similar to the key 178 and a flange 1063 similar to the flange 174. The diffuser coupling 1062 may be inserted through the hole 1061 into the wind diffuser 1060 and may then engage a groove in the PV module, such as the groove 114 in the PV module 102. The diffuser coupling 1062 may be rotated such that the key 1064 engages the keyway 130 as described above with particular reference to fig. 28. This embodiment may provide advantages over prior art wind diffusers and deflectors due to the simple and low cost connection method directly to the PV module frame.

Fig. 108-109 illustrate other embodiments of wind diffusers, deflectors, or shrouds (such as wind diffuser 1080). One way in which the wind diffuser 1080 may differ from the previously described embodiments may be: it consists of a single component, which may be, for example, a curved metal plate, a plastic plate, or the like, or may be extruded or otherwise formed, to name another example. The wind diffuser 1080 may consist of a tongue profile, shape, or protrusion (such as tongue 1081) that may be adapted to engage a groove in a PV module, such as groove 114 in PV module 102. Tongue 1081 may be shaped so as to bend up and down, or formed such as upper guide clip 1082 and lower guide clip 1083. The upper guide clip 1082 may be adapted to engage the keyway 130a and/or the bearing surface 124 (see fig. 4), and the lower guide clip 1083 may be adapted to engage the keyway 130b and/or the bearing surface 128 (see fig. 4). The wind diffuser 1080 may be constructed of a pliable or semi-pliable material (such as sheet metal or plastic, etc.) such that the tongue 1081 may be pliable or deflectable during installation such that the distance between the topmost point on the upper guide clip 1082 and the bottommost point on the lower guide clip 1083 may be less than the distance "n" as shown in fig. 4 a. Tongue 1081 may then enter groove 114, and may then be released such that the guide clip is engaged in the keyway. The wind diffuser 1080 may also include a flange or tab (such as a blocking flange 1084) that may be adapted to prevent the wind diffuser 1080 from entering too deeply into the groove 114. In some embodiments, tongue 1081 may be formed only in a portion of the length of wind diffuser 1080, while in other embodiments tongue 1081 may extend substantially the entire length of wind diffuser 1080. This embodiment may provide benefits over prior art wind diffusers and deflectors due to the simple and low cost connection method to the PV module frame.

Fig. 110-111 illustrate other embodiments of wind deflectors or shrouds (such as wind diffuser 1100) that may be connected to other brackets, clips, or couplings, such as bracket 1101. The bracket 1101 may be adapted to engage a recess in a PV module, such as recess 114 in PV module 102. The bracket 1101 may include a flange or tab (such as tab 1107) that may be adapted to attach to the wind diffuser 1100, such as by one or more rivets, screws, pins, welds, spring clips, press fit portions, and the like. The bracket 1261 may also include a hook-shaped flange or tab (such as the lower hook 1103) that may be adapted to engage the keyway 130b and the bearing surface 128 (see fig. 4) in the groove 114. To securely engage the bracket 1101 into the groove 114, the bracket 1101 may also include another hooked flange or tab (such as the above hook 1105) that may be attached to the bracket 1101, such as by or via a spring member, flange, or arm (such as the spring arm 1104). The spring arm 1104 may be adapted such that the spring arm 1104 may deflect toward the PV module 102 such that the upper hook 1105 may be forced downward and into the groove 114. When the spring arms 1104 are released, the upper hooks 1105 may engage the keyways 130a and the bearing surface 124, thereby securely attaching the wind diffuser 1100 to the PV module 102. The bracket 1101 may also include a surface or tab, such as a pushing surface 1106, for conveniently placing a thumb, hand, or tool of someone who may apply a force on the spring arm 1104. This embodiment may provide advantages over prior art wind diffusers and deflectors due to the simple and low cost connection method of snap connection to the PV module frame.

Additional embodiments of tilt interlocks (see, e.g., the tilt interlocks shown in fig. 37-38) are shown in fig. 112-117. In fig. 112, a structural system is shown that includes a tilt interlock (such as tilt interlock 1120), the tilt interlock 1120 may connect two, three, or four PV modules 102 together by connecting the PV modules 102 to the tilt interlock 1120 via a coupling and tongue as will be discussed in more detail below.

Tilt interlock 1120 may be constructed from steel plate, extruded aluminum, plastic, concrete, or any suitable rigid material. The tilt interlock 1120 is similar to many of the previously described structural systems except that it is composed of fewer components (i.e., support bodies such as the body 1121). In some embodiments, main body 1121 includes a coupling, such as coupling 1122, similar to attachment coupling 198 shown in fig. 27 and used to attach main body 1121 to a PV module frame (such as frame 112 in PV module 102). Body 1121 can also include integral features adapted to engage a frame of a PV module. Thus, in some embodiments, the body 1121 can be used as an interlock for coupling 2, 3, or 4 PV modules 102 together. Fig. 112 shows a main body 1121 having features for engaging a groove (such as groove 114) in a PV module frame, such as by a flange, tab, or pivot-fit tongue (such as tongue 1123). It is specifically contemplated that coupling 1122 and tongue 1123 can be replaced by an alternative coupling member, and body 1121 can be adapted to operate in conjunction with the alternative coupling member. For example, tongue 1123 may be replaced by an engagement feature similar to engagement portion 821 as shown in fig. 82 or a surrounding structural system similar to surrounding engagement portion 831 as shown in fig. 83. Also for example, the coupling 1122 can be replaced with a pivoting lock arm (such as a spring support 1161 as shown in fig. 116 and 117 and similar to the spring support 1013 shown in fig. 101), and the body 1121 is adapted for the pivoting lock arm. Note that the spring support 1161 is shown here in a perspective that can observe the underside of a flange 1171 on the main body 1121 that the lower portion 1170 exerts a force when in its final installed position.

Those skilled in the art will recognize that the body 1121 may also be adapted as a hollow body, extrusion or rail (such as rail 1150 in fig. 115 and rail 1160 in fig. 116) in which a channel may be formed or also be adapted with clips, flanges or tabs that may provide a means to attach ballast blocks or blocks (such as ballast blocks 751 as shown, for example, in fig. 75).

Fig. 118-119 illustrate another embodiment of a structural system, such as structural system 1180, for supporting a tilted PV module. Structural system 1180 may be constructed from steel plate, extruded aluminum, or any suitable rigid material. The structural system 1180 is similar to a plurality of previously described structural systems (such as the structural system 112 in fig. 112), except that it may be comprised of a body 1190 adapted to receive coupling members, structures, arms, legs, and the like (such as a lower leg 1191 and an upper leg 1192). The lower leg 1191 and the upper leg 1192 may be attached to the body 1190 such as by screws, rivets, clips, welds, etc., or as shown by keyed male and female features such as the slot 1193 and the tongue 1194. The upper leg 1192 can be adapted to connect to the PV module, such as by a coupling, clip, flange, or the like (such as a coupling 1195 similar to the accessory coupling 198 as shown in fig. 27). The lower leg 1191 may be adapted to connect to a PV module, such as by a coupling, clip, flange, or the like (such as a tongue 1196 similar to the tongue 1123 as shown in fig. 112). It should be recognized that the upper and lower legs 1192, 1192 may be interchanged with alternative lower and upper legs that may provide different heights or lengths to change the angle or position of inclination of the PV module.

Fig. 120-128 illustrate other embodiments of structural systems for supporting tilted PV modules, such as tilt interlock 1200. The tilt interlock 1200 may be constructed from steel plate, extruded aluminum, or any suitable stiff material. The tilt interlock 1200 is similar to a number of previously described structural systems, such as the tilt interlock 1120 in fig. 112, except that the main body 1121 is replaced by a main body 1201 that may be lower profile and may have other significant features as will be described below. For example, the body 1201 may include a spring clip or similar snap or latch type securing device (such as drop clip 1220) in place of the coupling 1122. In some embodiments, the body 1201 may include one or two drop-off clips 1220, typically the body 1201 includes 1 to 6 drop-off clips 1220, with additional clips for added strength. Drop-out clip 1220 can also be connected to a feature that extends substantially the length of body 1201, allowing the drop-out clip to be connected to PV module 102 near and away from the 4 corner knots of 4 PV modules 102. This feature may allow for more flexibility in installation because the tilt interlock 1200 may simply be connected to the PV module 102 at various locations along the length of the frame 112. It is also possible to install a tilt interlock 1200 at the 4-corner junction and additional tilt interlocks between these areas, thereby increasing the overall strength and/or stiffness of the structural system. For example, additional tilt interlocks 1200 may be installed between tilt interlocks 1200 as shown in fig. 120. The body 1201 of this embodiment may also include a pivot-fit mechanism, such as a pivot-fit retainer 1226.

The main body 1201 as shown in fig. 122 may include a portion adapted to interlock the PV modules 102 together along the leading or lower edges, such as a leading end interlock portion 1221, and a portion adapted to interlock the PV modules 102 together along the trailing or upper edges, such as a trailing end interlock portion 1222. The front end interlocking portion 1221 and the back end interlocking portion 1222 may be used to interlock the PV modules 102 in a row, or may connect a row end module 102 to the main body 1201 and thus to the next end module in an adjacent row (as shown in fig. 120). As is more evident from viewing the diagram 120, the difference in height between the front end interlocking portion 1221 and the rear end interlocking portion 1222 may cause the module 102 to tilt relative to the plane of the roof or support structure (not shown), thereby enabling the creation of tilted rows of PV modules 102 to form the entire PV array 1202. Fig. 121 provides a side view showing each row of PV modules 102 in PV array 1202 at an approximately 5 degree angle of inclination relative to horizontal. Typically, the rows may be tilted between 3 to 30 degrees by varying the height difference between the front end interlocking portion 1221 and the back end interlocking portion 1222 and/or the width of the PV module 102. The width of body 1201 may be optimized to minimize power consumption caused by inter-row shadowing effects. For example, the present embodiment contemplates a distance to height ratio of 2.5 to 1 when comparing the horizontal distance between the top surfaces of PV modules 102 in two adjacent rows (dashed line D in fig. 121) to the vertical height between the top surfaces (dashed line H in fig. 121). Other embodiments contemplate distance to height ratios in the range of 1 to 10 to 1. Fig. 121 indicates with dashed lines that the body 1201 may be shortened or lengthened, thereby decreasing or increasing the height to distance ratio. The body 1201 may also include a generally horizontal portion or surface, such as a body top surface 1223, which may provide a movable surface that allows the installer to simply rest on the body 1201 rather than over the body 1201 when moving between rows of PV modules 102 in the PV array 1202. The body 1201 may also include generally flat facing lower portions, such as a front base portion 1224 and a rear base portion 1225, adapted to rest on or connect to a roof surface. In some embodiments, the front base portion 1224 and the rear base portion 1225 may include rubber or other softer materials to prevent the body 1201 from damaging the roof. As shown in fig. 122, the front base portion 1224 and the rear base portion 1225 may include flanges that project from each other and generally below the main body 1201 to retain this ballast or similar ballast material when the necessary ballast blocks 751 resist local wind uplift loads. In some embodiments, adjacent bodies 1201 are joined by a wind diffuser 980 similar to that shown in fig. 98 or 1000 shown in fig. 100. In other implementations, as will be discussed below with respect to fig. 128, the body 1201 may also function as a wind diffuser. In some embodiments, the front base portion 1224 and the rear base portion 1225 may further include screws, bolts, clamps, or standoffs for actively securing the body 1201 to a roof or support structure. In still other embodiments, the shape of body 1201 may be optimized via calculations and/or wind tunnel modeling to eliminate the need for ballast and/or positive attachment to a roof.

Referring to fig. 122-123, drop clip 1220 can be constructed of bent spring steel, plastic, or other substantially stiff material that is resilient in the direction of spring travel (see below). For example, the drop clip 1220 as shown in fig. 123 may include a lower spring or resilient portion (such as a lower spring 1232) for engaging the underside of the PV module 102 and an upper spring (such as an upper spring 1233) for snap-engaging the groove 114 in the PV module 102. Drop clip 1220 can also include an engagement portion, such as engagement portion 1230, for being at least partially occupied by a portion of body 1201 and a stiffening flange, such as stiffening flange 1231, for providing stiffness (see below) in a direction opposite the facing face of PV module 102. In some embodiments, the engagement portion 1230 may be loosely attached (for ease of field positioning) by sliding into the clip attachment portion 1227, while in other embodiments, the engagement portion may be secured to the body 1201 or press fit or molded into the clip attachment portion 1227. The lower spring 1232 may include a grounding portion, such as grounding tab 1234, adapted to deform a portion of the PV module frame 112 to create a grounding engagement between the drop clip 1220 and the PV module frame 112.

In some embodiments, drop clip 1220 is a one-piece construction, and in other embodiments, drop clip 1220 comprises multiple pieces. For example, drop clip 1220 as shown in fig. 123 includes a first piece including upper spring 1233 and lower spring 1232 and a second piece including body 1239. As shown in fig. 123, the upper spring 1233 may include a horizontally or slightly downwardly angled tab, flange, or portion, such as a retaining portion 1235, the function of which will be described in greater detail below. As described in more detail below, drop clip 1220 can provide a simple and quick method of connecting PV module 102 to rear interlock portion 1222, enabling quick installation and coupling of adjacent PV modules 102.

Additional portions of the tilt interlock 1200, specifically the portion of the tilt interlock 1200 that enables the PV module 102 to be connected to the front or lower end or side of the main body 1201 are shown in fig. 124-125. The pivot-fitting retainer 1226, as shown in the perspective of fig. 124, may be made of stamped, bent, extruded, molded metal or plastic or other suitable material, and may be connected to the body 1201 in any of the ways mentioned above for connecting the drop clip 1220 to the body 1201. One or more (typically 1 to 6) pivot-fit retainers 1226 form a front interlocking portion 1221 along with the front of the main body 1201, which can enable quick pivot-fit coupling of adjacent PV modules in the PV array 1202. The pivot mating retainers 1226 may include a generally horizontal portion, such as the frame engagement portion 1240, for encircling the frame 112 or the coupling groove 114. In some embodiments, such as this embodiment, the frame engaging portion 1240 can also include a guide clip 1241 for resisting horizontal disengagement from the frame 112. The pivot-fit holder may also include a mechanism or fastener for connecting to the main body 1201, such as a main body engagement portion 1242. In some embodiments, the body engagement portion can also include a deformation edge 1243, which can help secure and/or provide a reliable ground between the pivot mating retainer 1226 and the body 1201. As shown in fig. 25, the pivot-fit holder is connected to a main body 1201. The PV module 102 can then be connected to the interlocking portion 1221 via a pivot-fit action, first holding the PV module 102 at an insertion angle, moving it in the direction labeled a, and then rotating it in the direction labeled B. As can be seen in the final connection position of PV module 102 (shown in phantom in fig. 25), offset bearing surface 128 and lower bearing surface 1250 are horizontally offset to achieve a secure connection between frame 112 and interlock 1221 similar to the other pivot fit connections described above.

Fig. 126-127 illustrate the connecting action of the rear interlocking portion 1222 when the PV module 102 is inserted and rotated downward as shown in fig. 125. With the PV module 102 held in the position shown in fig. 126, the body 1201 is moved in direction a towards the PV module 102. Once the drop clip body 1236 contacts the frame 112 (as indicated by the dashed lines presented in fig. 126), the PV module 102 is lowered downward in direction B. Those skilled in the art will recognize that downward movement of the frame 112 pushes the upper spring 1233 to the left and then begins to push the lower spring 1232 downward. As the downward motion continues, the upper spring can slide along the underside of the frame 112 until the opening of the groove 114 is reached, at which time the upper spring 1233 snaps to the right and engages the lower surface 126 (see fig. 4). In the final connected position shown in fig. 127, the lower spring 1232 may exert an upward force on the frame 112 and the upper spring may exert a force on the right, effectively connecting the PV module 102 to the rear interlock portion 1222. Because the highest loads in the PV array 1202 are generally vertical (up and down), the upper springs 1233 (whose pitch direction is from left to right) can resist the upward vertical load along their strongest axis, and the lower springs 1232 can be substantially prevented from resisting the downward vertical load as the frame 112 can contact the body portion as shown in fig. 127.

Fig. 128 shows a top view of a PV array (such as PV array 1282) including a body 1281. PV array 1282 is similar to PV array 1202 except that body 1281 is longer than body 1201 and includes a length approximately equal to 0.75 times the length of PV module 102. This embodiment contemplates a body 1281 length that is 0.5 to 1 times the length of the PV module 102, with the exact length calculated to minimize the rise due to wind. In this embodiment, the length of the body 1281 allows for close packing of more space between the body at the end of the row (right side of fig. 128) and the body in a non-peripheral location. This configuration has advantages in common conditions such as higher wind pressure near the periphery of the PV array 1282 and lower wind pressure inside the PV array 1282. Body 1281 also includes a length that allows for little or no protrusion of body 1281 material outward from the ends of a row of PV modules 102 in PV array 1282. This feature allows for better density of PV modules 102 on the roof than many prior art systems.

Fig. 129 to 131 show an alternative embodiment of a structural system having features similar to the embodiment described in fig. 120 to 128, except that this embodiment contemplates a structural system optimized to create individual rows 1300 of PV modules 102 instead of tilt interlocks that can connect PV modules 102 within a row and between rows. As shown in fig. 129, structural system 1290 may comprise rails, beams, or pan-like elements, such as base 1291, for spanning a substantially horizontal distance below PV module 102. The base 1291 can be connected to the front and rear interlocking portions 1293 and 1294, which can be similar to the front and rear interlocking portions 1221 and 1222, respectively, as described above, via fasteners, rivets, press fits, and the like. In some embodiments, the front and rear interlocking portions 1293 and 1294 are rotatably connected to the base such that each can be rotated to flatten for easier packaging and handling. The front 1293 and rear 1294 interlocking sections can include a pivot fit holder 1295 and a drop clip 1296, each of which can be similar to similar devices described in previous embodiments. Base 1291 may also include ballast blocks 1297. The advantages of this embodiment may be: multiple mechanically independent rows may be constructed on a roof with multiple obstacles (such as electrical equipment, grounding equipment, lighting protection equipment, mechanical equipment, etc.) located between the rows.

Fig. 132-133 illustrate an alternative embodiment of a tilt foot as discussed in previous embodiments, such as tilt foot 650, tilt foot 770, tilt foot 800, tilt foot 810, tilt foot 820, and tilt foot 830. The tilt foot 1320 operates in a manner similar to many of the previously described tilt feet, except that the tilt foot 1320 may engage a track, such as track 1321, in a substantially external manner relative to the interior of a channel, such as channel 697 as previously discussed. The deforming edge 676 as previously discussed is replaced by a deforming edge 1322 that deforms the outer surface of the track 1321 or cuts the outer surface of the track 1321 when the ramp 1320 rocks to engage the track 1321. The spring clip 671 is here replaced by a fastener, pin or press-fit device, such as a threaded fastener 1323 or pin 1324. To attach the tilt foot 1320 to the track 1321, the tilt foot 1320 may be tilted to an angle that slides around the track 1321, rotated clockwise, and then attached to the track via the pin 1324. The slant foot may also include an interlock portion 1325 that may operate in a manner similar to interlock 651.

Fig. 134-135 show an alternative embodiment of a tilt interlock similar to the tilt interlock 1200, except that the drop down clip 1220 can be replaced with one or more spring brackets (such as spring brackets 1340, 1341) to connect the tilt interlock (such as tilt interlock 1342) to one or both PV modules 102. The spring supports 1340, 1341 may differ from the spring support 1161 as previously discussed in that: which is manual (spring bracket 1341 rotates clockwise and spring bracket 1340 rotates counterclockwise) and one spring bracket, such as spring bracket 1340, connects only one PV module 102 to the tilt interlock. Fig. 134 illustrates an end-of-line condition, but those skilled in the art will recognize that using a tilt interlock instead of the centermost tilt interlock 1200 in fig. 120 will result in a spring bracket 1341 coupling a first PV module 102 to interlock 1342 and a spring bracket 1340 coupling a second PV module 102 to interlock 1342, resulting in the first PV module 102 coupling the second PV module 102. The spring supports 1340, 1341 can include a generally C-shaped portion 1343 that can be positioned such that when it is held at a first angle (indicated by the solid line representation of the spring supports 1340, 1341), the upper horizontal portion is at least partially in the groove 114 (or in other embodiments, on top of the frame 112) and the lower horizontal portion is below the ledge 1344 on the tilt interlock. Rotation of each spring bracket 1340, 1341 to the position indicated by the dashed lines causes the C-shaped portion to apply a downward force to bearing surface 128 and an upward force to flange 1344, thereby connecting PV module 102 to the tilt interlock. The tab 1345 functions substantially the same as the tab 1053 as previously described. In other embodiments, the spring supports 1340, 1341 replace the C-shaped portion 1343 with an I-shaped portion and a double tab and thus may be reversed and not manually controlled.

Fig. 136-138 illustrate another alternative embodiment of a tilt interlock that may be similar to the tilt interlock 1200, except that the drop down clips 1220 may be replaced with one or more pivoting mating brackets, such as the pivoting mating bracket 1360, to connect the tilt interlock, such as the tilt interlock 1342, to one or both PV modules 102. The pivot engagement brackets may include tongue portions 1363 that operate in a similar manner to the pivot engagement tongue portions previously described to connect the pivot engagement brackets 1360 and thus the tilt interlocks 1362 to the grooves 114. Fig. 138 illustrates the insertion and final positions of the tilt interlock 162 when the tilt interlock 162 is connected to a PV module 102 or a pair of adjacent PV modules 102. The pivot mating brackets 1360 may be connected to the tilt interlocks 1362 via removable fasteners 1361, enabling withdrawal by loosening the fasteners 1361, reversing the pivot mating brackets, and then reversing the drop order of the PV modules as previously described to remove one PV module 102 from the middle of the array of PV modules 102. This embodiment may simplify installation.

Fig. 139 through 140 illustrate another alternative embodiment of a tilt interlock that may be similar to the tilt interlock 1200, except that the drop down clip 1220 may be replaced with one or more slide-in brackets (such as slide-in bracket 1390) to connect the tilt interlock (such as tilt interlock 1392) to one or both PV modules 102. The slide-in bracket connects the flanges on the tilt interlock 1392 to the frame 112 by sliding into the position as shown by the arrow in fig. 139. The slide-in bracket 1390 may include sharp edges (such as edges 1393, 1394) for deforming the material and creating a ground engagement, and it may also surround the bearing surface 128 and flange 1395 or it may surround the top of the frame 112 and flange 1395. This embodiment may reduce materials and reduce costs.

While various exemplary aspects and embodiments have been discussed above, those of skill in the art will recognize certain modifications, permutations, additions and sub-combinations thereof. It is therefore intended that the following appended claims and claims hereafter introduced are interpreted to include all such modifications, permutations, additions and sub-combinations as are within their true spirit and scope.

Claims (8)

1. An L-bracket for mounting a photovoltaic module, comprising:

an interlock (651) mounted on the L-bracket, the interlock adapted to engage a recess (114) in a PV module (102), wherein the interlock comprises:

a plate (660),

a vertical wall (666) extending upwardly from the plate (660), an

Outwardly angled flanges (661) extending from opposite ends of said plate (660) and comprising a height enabling at least partial insertion into recess (114) when PV module (102) is at an insertion angle relative to said interlock (651); and

a spring clip (671) mounted on a second end (670) of the L-bracket, the spring clip configured to snap onto a rail (690).

2. The L-bracket of claim 1 wherein the first and second angled flanges of the interlock (651) are arranged to engage with first and second PV modules, respectively.

3. The L-bracket of claim 2 wherein said interlocking (651) first and second angled flanges extend in a direction perpendicular to said L-bracket.

4. The L-bracket of claim 1, wherein the spring clip is configured to be received in an inner surface of the track.

5. The L-bracket of claim 1 wherein the angled flange comprises a cutting edge.

6. An L-shaped bracket according to claim 1, wherein the L-shaped bracket further comprises a rocking surface.

7. An L-shaped bracket as defined in claim 1 wherein the first end of the L-shaped bracket includes a deformable rim extending therefrom.

8. The L-bracket of claim 1, wherein the spring clip is configured to flex inwardly from an initial position when installed in an interior channel of the rail and to flex back to the initial position after being installed to snap into the interior channel of the rail.