Photovoltaic module mount

Patent metadata

Field	Value
Publication number	US-10171027-B2
Application number	US-201514923373-A
Country	US
Kind code	B2
Filing date	Oct 26, 2015
Priority date	Mar 2, 2015
Publication date	Jan 1, 2019
Grant date	Jan 1, 2019

Abstract

Mounting components of photovoltaic (PV) modules and PV module assemblies are described, including PV module couplings and PV module mounting chassis. In an example, a PV module includes a PV module coupling having a toe portion extending from a PV module frame, and a PV module mounting chassis includes a toe slot to receive the toe. The toe and toe slot construction allows for the PV module frame to be assembled to the PV module mounting chassis without using tools, and thus, permits a PV module assembly to be quickly constructed during installation of a PV module system. Furthermore, the toe and toe slot construction accommodates thermal expansion and other environmental loads seen after installation, while providing a grounding connection for the PV module assembly.

First claim

What is claimed is:

1. A photovoltaic (PV) module coupling, comprising:
a body plate having an upper surf ace along a first plane between a first end and a second end;
a retainer extending downward from the second end, wherein the retainer includes a retention surface along a second plane orthogonal to the first plane; and
a toe extending orthogonal to the second plane from the retainer to a terminal edge, the PV module to couple to a module stand, wherein the module stand includes a base portion and an upright extending from the base portion to a support surface, wherein the module stand further includes a locking plate having a locking surf ace coupled to the upright, and wherein the locking plate includes a locking toe slot through the locking surface, wherein the module stand further includes a pair of alignment protrusions extending upward from the support surface, wherein the pair of alignment protrusions define a rail notch between the pair of alignment protrusions and the support surface, and wherein the rail notch is longitudinally aligned with the locking toe slot.

2. The PV module coupling of claim 1 further comprising a first alignment tab extending upward from the body plate.

3. The PV module coupling of claim 2 , wherein the upper surface is between a first sidewall and a second sidewall of the body plate, and wherein the first alignment tab extends from the first sidewall.

4. The PV module coupling of claim 3 further comprising a second alignment tab extending from the second sidewall, wherein the first and second alignment tabs include respective inward surfaces facing each other across the upper surface of the body plate, and wherein the inward surfaces are separated by a distance greater than a width of the upper surface.

5. The PV module coupling of claim 1 , wherein the body plate includes a port through the upper surface.

6. The PV module coupling of claim 5 , wherein the body plate, the retainer, and the toe are at least partially composed of stainless steel.

7. A photovoltaic (PV) module mounting chassis, comprising:
a bridging member having an elongated body between a first end and a second end; and
a grounding plate coupled to the elongated body at the first end, the grounding plate including
a toe receiving portion including (a) an upper receiving surface and (b) an upper toe slot through the upper receiving surface,
a contact portion including a contact surface vertically higher than the upper receiving surface, and wherein the contact surface is electrically connected to the second end through the bridging member; and

a module stand coupled to the elongated body at the second end, wherein the module stand includes a base portion and an upright extending from the base portion to a support surface, wherein the module stand further includes a locking plate having a locking surf ace coupled to the upright, and wherein the locking plate includes a locking toe slot through the locking surface, wherein the module stand further includes a pair of alignment protrusions extending upward from the support surface, wherein the pair of alignment protrusions define a rail notch between the pair of alignment protrusions and the support surface, and wherein the rail notch is longitudinally aligned with the locking toe slot.

8. The PV module mounting chassis of claim 7 , wherein the contact portion includes a spring contact having the contact surface, and wherein the spring contact is resiliently deflectable.

9. The PV module mounting chassis of claim 8 further comprising a tab plate coupled to the elongated body at the second end, wherein the tab plate includes a tab extending vertically upward.

10. The PV module mounting chassis of claim 9 , wherein the locking plate is attached to the upright at a hinge point and the locking surface is resiliently deflectable away from the upright about the hinge point.

11. The PV module mounting chassis of claim 10 , wherein the locking plate further includes a striking surf ace extending from an upper edge of the locking surf ace at an oblique angle to the support surface.

12. The PV module mounting chassis of claim 11 , wherein the elongated body includes a pair of elongated rails, wherein the grounding plate extends between the pair of rails at the first end, wherein the base portion extends between the pair of rails at the second end, and wherein the upper toe slot and the locking toe slot are longitudinally aligned between the pair of rails.

13. The PV module mounting chassis of claim 12 , wherein the base portion includes a side receiving surface and a side toe slot through the side receiving surface.

14. A photovoltaic (PV) module mounting assembly, comprising:
a PV module mounting chassis including
a grounding plate having a toe receiving portion, the toe receiving portion having an upper toe slot in an upper receiving surface,
a module stand including an upright having a support surface vertically higher than the upper receiving surface, wherein the module stand further includes a locking plate having a locking surf ace coupled to the upright, and wherein the locking plate includes a locking toe slot through the locking surface, wherein the module stand further includes a pair of alignment protrusions extending upward from the support surface, wherein the pair of alignment protrusions define a rail notch between the pair of alignment protrusions and the support surface, and wherein the rail notch is longitudinally aligned with the locking toe slot, and
a bridging member having a first member end and a second member end, the bridging member coupled to the grounding plate at the first member end and coupled to the module stand at the second member end; and

a PV module frame including
an elongated frame rail having an underside between a first rail end and a second rail end, wherein the underside is mounted on the support surface at the second rail end, and
a first PV module coupling including a body plate, a retainer, and a toe, wherein the body plate is coupled to the underside of the frame rail at the first rail end, the retainer extends from the body plate through the upper toe slot of the toe receiving portion, and the toe extends from the retainer to a terminal edge underneath the upper receiving surface.

15. The PV module mounting assembly of claim 14 , wherein the grounding plate includes a contact portion having a contact surface vertically higher than the upper receiving surface, and wherein the underside of the frame rail is mounted on the contact surface at the first rail end to electrically connect the grounding plate to the module stand through the frame rail.

16. The PV module mounting assembly of claim 15 , wherein the module stand further includes a locking plate having a locking surf ace attached to the upright, wherein the locking plate includes a locking toe slot through the locking surf ace, and wherein the PV module frame further includes a second PV module coupling having a second body plate and a second toe, wherein the second body plate is coupled to the underside of the frame rail at the second rail end, and the second toe extends through the locking toe slot.

17. The PV module mounting assembly of claim 16 , wherein the locking plate includes a striking surf ace extending from an upper edge of the locking surf ace at an oblique angle to the support surface, and wherein the second toe extends through the locking toe slot to a second terminal edge below the striking surface.

Assignees

• Sunpower Corp

Inventors

• Wares Brian S
• Ripoll Agullo Vicent
• Grushkowitz Tyler

Classifications

• H02S20/30

  Supporting structures being movable or adjustable, e.g. for angle adjustment · CPC title

• F24S2025/6007

  by using form-fitting connection means, e.g. tongue and groove · CPC title

• Y02E10/47

  Mountings or tracking · CPC title

• H02S40/36

  characterised by special electrical interconnection means between two or more PV modules, e.g. electrical module-to-module connection · CPC title

• F24S2025/6002

  by using hooks · CPC title