PATENT DOCUMENT

Publication Number: US-10309690-B2
Application Number: US-201815866116-A
Country: US
Kind Code: B2

Title: Discrete attachment point apparatus and system for photovoltaic arrays

Abstract:
An attachment point apparatus and system for photovoltaic arrays is disclosed. One embodiment provides a rail system for receiving a PV module, including a first rail, a second rail, a substantially rectilinear double male connector adapted for coupling an end of the first rail to an end of the second rail, and a connector adapted to attach a PV module to the first rail. Another embodiment provides a PV module including a PV laminate, a frame integral with and supporting the PV laminate, and a spanner bar adapted to solely span a width of the PV module, orthogonally connect at various locations along the frame, and attach to a support structure. A further embodiment provides a coupling device for a PV module comprising a first coupling portion adapted to rotatably engage a PV module, and a second coupling portion adapted to rotatably engage a rail.

Claims:
What is claimed is: 
     
       1. A photovoltaic (PV) module mounting system, comprising:
 a first section of rail; 
 a second section of rail; 
 a splicing connector splicing an end of the first section of rail to an end of the second section of rail; and 
 a PV module connector adapted to support a PV module above the splicing connector, the PV module connector comprising a base connector portion having a rotating foot that fits into a groove formed in the splicing connector, wherein the rotating foot fits into the groove in a first position and the rotating foot locks into the groove in a second position. 
 
     
     
       2. The PV module mounting system as recited in  claim 1 , wherein the splicing connector comprises a spring clip that provides retention and grounding between the splicing connector and the first section of rail. 
     
     
       3. The PV module mounting system as recited in  claim 1 , wherein the PV module connector is a double male PV module coupling configured to support two adjacent PV modules. 
     
     
       4. The PV module mounting system as recited in  claim 1 , wherein the groove formed in the splicing connector extends across a length of the splicing connector. 
     
     
       5. The PV module mounting system as recited in  claim 4 , wherein a first end of the splicing connector is disposed within an interior volume defined by the first section of rail and a second end of the splicing connector is disposed within an interior volume defined by the second section of rail. 
     
     
       6. The PV module mounting system as recited in  claim 1 , wherein the PV module connector comprises an interlock configured to engage a first side of a first PV module and a second side of a second PV module. 
     
     
       7. A photovoltaic (PV) module assembly, comprising:
 a first rail; 
 a second rail; 
 a PV module; 
 a splicing connector splicing an end of the first rail to an end of the second rail; and 
 a PV module connector supporting the PV module above the splicing connector, a first end of the PV module connector coupled directly to the splicing connector and a second end of the PV module connector coupled to the PV module. 
 
     
     
       8. The PV module assembly as recited in  claim 7 , wherein the first and second rails define first and second respective interior volumes and wherein a first portion of the splicing connector is disposed within the first interior volume and a second portion of the splicing connector is disposed within the second interior volume. 
     
     
       9. The PV module assembly as recited in  claim 7 , further comprising a spring clip wrapped around the splicing connector and forming a grounding path between the splicing connector and one of the first rail and the second rail. 
     
     
       10. The PV module assembly as recited in  claim 7 , wherein the splicing connector includes a first opening for receiving a threaded stud of the PV module connector and a second opening for receiving a threaded stud of another PV module connector. 
     
     
       11. The PV module assembly as recited in  claim 7 , wherein the first rail comprises a hollow tube having a rectangular cross-sectional geometry. 
     
     
       12. The PV module assembly as recited in  claim 11 , wherein the splicing connector has a rectangular cross-sectional geometry and fits within the hollow tube. 
     
     
       13. The PV module assembly as recited in  claim 7 , wherein the splicing connector defines a channel and the PV module connector is coupled directly to the splicing connector by engaging the channel. 
     
     
       14. The PV module assembly as recited in  claim 13 , wherein the first end of the PV module connector has a size and shape in accordance with the size and shape of the channel defined by the splicing connector. 
     
     
       15. A photovoltaic (PV) module mounting system, comprising:
 a first section of rail; 
 a second section of rail; 
 a splicing connector splicing an end of the first section of rail to an end of the second section of rail; and 
 a PV module connector adapted to support a PV module above the splicing connector, the PV module connector comprising a threaded stud engaged within a tapped hole defined by the splicing connector. 
 
     
     
       16. The PV module mounting system as recited in  claim 15 , wherein the PV module connector is configured to support both a first PV module and a second PV module adjacent to the first PV module. 
     
     
       17. The PV module mounting system as recited in  claim 15 , further comprising a spring clip disposed between the splicing connector and the first section of rail, the spring clip providing retention and grounding between the splicing connector and the first section of rail. 
     
     
       18. The PV module mounting system as recited in  claim 15 , wherein the PV module connector is a first PV module connector and the PV module mounting system further comprises a second PV module connector engaged within another tapped hole defined by the splicing connector. 
     
     
       19. The PV module mounting system as recited in  claim 15 , wherein the first and second sections of rail are coupled to discrete locations on a PV ground mount structure. 
     
     
       20. The PV module mounting system as recited in  claim 15 , wherein a first end of the splicing connector is disposed within a first interior volume defined by the first section of rail and a second end of the splicing connector is disposed within a second interior volume defined by the second section of rail.

Description:
CROSS-REFERENCES TO RELATED APPLICATIONS 
     The present application is a divisional of U.S. application Ser. No. 13/402,860, filed Feb. 22, 2012, which is a continuation of U.S. application Ser. No. 13/325,054, filed Dec. 13, 2011, and claims the benefit of the filing date of U.S. Provisional Patent Application Ser. No. 61/445,044, filed Feb. 22, 2011. The foregoing applications are incorporated by reference in their entirety as if fully set forth herein. 
    
    
     BACKGROUND OF THE INVENTION 
     Many photovoltaic (PV) arrays are mounted on structures that require discrete attachment points. For example, tile and slate roofs and various types of ground mounted structures may include a support structure for a PV array that requires attachment of the PV array to the structure at discrete locations in one of or both the x and y axes of a PV array mounting plane. In the case of tile roofs, this may be due to the difficulty of installing an attachment device at anywhere other than a specific place relative to the tile. For example, some tile products may only allow an attachment device to be installed within a small range of the overall reveal (length showing) of the tile and the underlying roof may require attachment to the rafters, which typically runs on a discrete schedule. Thus, locations for mounting along the y-axis may be restricted as by the tile and locations for mounting along the x-axis may be restricted as by the locations of the rafters. Ground mount structures may also require discrete attachment points in the x and/or y axes as may be due to fixed locations of the structural members and/or the need to line up the structural members with specific locations on the PV module. 
     Some attempts have been made to address the need for discrete attachment point mounting systems. Most utilize long rails to span between discrete attachment points, thereby freeing up the x and/or y axes. The rails may be connected directly to the PV module frame as by a compression clamp. The rails may be connected to the support structure below as by means of an attachment device such as a tile hook, standoff, hanger bolt, false tile, or mounting foot. 
     Such conventional systems suffer from a number of drawbacks. The long rails utilized, which can be often 10-20 feet long, may be difficult to warehouse, ship, and move onto a roof, or other support surface. These rails may also limit mounting options on complicated roofs which may have numerous smaller roof surfaces and/or numerous obstructions (such as vent pipes, chimneys, and so on) since rails may need to be cut on site, potentially wasting time and materials. Since rafters typically run in the direction from ridge to gutter, conventional long rail systems may be less cost-effective if the PV modules are oriented in “landscape” as opposed to “portrait” manner, since rails parallel to the rafters may require more total rail length or be prohibited, as by the PV module manufacturer or local building codes. 
     The mounting technology used to connect PV modules to these described long rails may also be cumbersome and time-consuming due to large numbers of small parts, including fasteners. The attachment devices utilized may also be expensive and time-consuming to install. Such conventional systems may further suffer from a lack of adaptability to uneven roof surfaces as well as time-consuming and unreliable grounding hardware. There may also be very little integration with other required equipment in the overall PV system, such as electrical junction and combiner boxes, wire management devices, and other equipment. 
     Prior discrete attachment point systems may frequently require more attachment devices than needed for acceptable structural performance of the system. For example, typical tile roof mounting systems, which may not interconnect the rows, may require two rows of rails per row of PV modules. This constraint may limit the ability of a system designer to optimize the structural support system so that the level of support provided is substantially matched to the level of support required, based on various site conditions such as wind, snow, roof structure, and so on. Lack of structural optimization could waste a significant quantity of materials relative to a more optimized approach. 
     The foregoing examples of the related art and limitations related therewith are intended to be illustrative and not exclusive. 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 figures. 
     BRIEF SUMMARY OF THE INVENTION 
     A discrete attachment point apparatus and system for photovoltaic arrays is disclosed. The following embodiments and aspects thereof are described and illustrated in conjunction with systems, apparatus, tools, and methods which are meant to be exemplary and illustrative, not limiting in scope. In various embodiments, one or more of the above-described problems have been reduced or eliminated, while other embodiments are directed to other advantages or improvements. 
     One embodiment provides a rail system for receiving a PV module, including a first rail, a second rail, a substantially rectilinear double male connector adapted for coupling an end of the first rail to an end of the second rail, and a connector adapted to attach a PV module to the first rail. Another embodiment provides a PV module including a PV laminate, a frame integral with and supporting the PV laminate, and a spanner bar adapted to solely span a width of the PV module, orthogonally connect at various locations along the frame, and attach to a support structure. A further embodiment provides a PV module including a PV laminate, a frame integral with and supporting the PV laminate, and a spanner bar adapted to orthogonally connect to various locations along the frame, and to attach to a support structure, wherein a length of the spanner bar is substantially an integer multiple of a width of the PV module. Another embodiment provides a coupling device for a PV module comprising a first coupling portion adapted to rotatably engage a PV module, and a second coupling portion adapted to rotatably engage a rail. A further embodiment provides a PV module including a PV laminate, a frame integral with and supporting the PV laminate, and a coupling device, wherein the coupling device comprises an upper engaging portion adapted to rotatably engage the frame and a lower engaging portion adapted to rotatably engage a rail. 
     In addition to the exemplary aspects and embodiments described above, further aspects and embodiments will become apparent by reference to the figures and by study of the following detailed descriptions. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       Demonstrative embodiments are illustrated in referenced figures and drawings. It is intended that the embodiments and figures disclosed herein are to be considered illustrative rather than restrictive. 
         FIG. 1A  shows a perspective view of a PV array on a roof. 
         FIG. 1B  shows a perspective view of a portion of an array on a roof. 
         FIG. 1C  is a perspective view of an interlock. 
         FIG. 2  is a perspective view of a PV module with a skirt. 
         FIG. 3  shows a perspective view of a cam foot in contact with a PV array over spanner bars. 
         FIG. 4  is a cutaway view of a spanner bar. 
         FIG. 5  is a perspective view of a cam foot inserted into a cutaway spanner bar. 
         FIG. 6A  and  FIG. 6B  is a perspective view of a cam foot. 
         FIGS. 7A and 7B  is a perspective view of a cam foot inserted into a spanner bar. 
         FIG. 8  is a perspective view of a spanner bar connected to a tile hook. 
         FIG. 9A  is a perspective view of two spanner bars with a double male connector. 
         FIG. 9B  is a perspective view of two spanner bars, which are connected. 
         FIG. 9C  is a perspective view of two spanner bars with a double male connector. 
         FIG. 9D  is a perspective view of two spanner bars, which are connected. 
         FIG. 9E  is a perspective view of a spanner bar with a double male connector. 
         FIGS. 10A and 10B  are side views of a skirt connecting to a cam foot. 
         FIGS. 11A and 11B  are side views of a cam foot connecting to a skirt and a PV module. 
         FIG. 12  is a perspective view of a roof with tile hooks. 
         FIG. 13  is a perspective view of a roof with tile hooks and spanner bars. 
         FIG. 14  is a perspective view of a roof with tile hooks and spanner bars. 
         FIG. 15  is a perspective view of a roof with tile hooks and spanner bars. 
         FIG. 16  is a perspective view of a roof with tile hooks and spanner bars and skirts. 
         FIG. 17  is a perspective view of a roof with tile hooks, spanner bars, and a PV modules. 
         FIG. 18A  is a perspective view of two spanner bars each with a double male connector. 
         FIG. 18B  is a perspective view of two connected spanner bars. 
         FIG. 18C  is a perspective view of an enlargement of an end of a spanner bar showing a double male connector. 
         FIG. 19  is a perspective view of a spanner bar connected to a tile hook. 
         FIG. 20  is a perspective view of a PV array with spanner bars and tile hooks. 
         FIG. 21  is an enlarged perspective view of a portion of a PV module and spanner bar. 
         FIG. 22  is a perspective view of a PV module, spanner bar, and tile hooks. 
         FIG. 23  is a side view of a PV module and tile hooks. 
         FIG. 24  is an enlarged perspective view of a portion of a PV module and spanner bar. 
         FIG. 25  is a side view of a PV module, spanner bars, and tile hooks. 
         FIG. 26  is an enlarged perspective view of a portion of a PV module and spanner bars. 
         FIG. 27  is an enlarged perspective view of a portion of a PV module and spanner bars and a tile hook 
         FIG. 28  is a perspective view of PV modules, spanner bars, and tile hooks. 
         FIG. 29  is a perspective view of PV modules, spanner bars, and tile hooks. 
         FIG. 30  is an enlarged perspective view of a portion of two PV modules and an interlock. 
         FIG. 31  is a perspective view of a PV array showing spanner bars and tile hooks. 
         FIG. 32  is a perspective view of a PV array showing spanner bars and tile hooks. 
         FIG. 33  is a perspective view of a coupling. 
         FIG. 34  is a perspective view of two spanner bars and a coupling. 
         FIG. 35  is an enlarged view of a portion of  FIG. 34 . 
         FIG. 36  is a perspective view of a portion of a spanner bar and a coupling. 
         FIG. 37  is a side view of  FIG. 36 . 
         FIG. 38  is am enlargement of a section of  FIG. 39 . 
         FIG. 39  is a perspective view of two spanner bars and a coupling. 
         FIG. 40  is a perspective view of two spanner bars and a coupling. 
         FIG. 41  is an enlargement of a portion of  FIG. 40 . 
         FIG. 42  is a perspective view of a PV array and a ground mount structure. 
         FIG. 43  is an enlargement of a portion of  FIG. 42 . 
         FIG. 44  is an enlargement of a portion of  FIG. 42 . 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     Terms. With reference to the figure and description herein: 
     Adjacent refers to being positioned next to or adjoining or neighboring, or having a common vertex or common side. Thus, adjacent PV panels would include PV panels that have one side close to (from a few inches apart to abutting) and facing one side of another PV panel, such as shown in  FIGS. 1 a    and  20 . Sometimes, but not always, the corners of adjacent panels align; so four adjacent panels would have one corner each that nearly or actually touch the other three corners, such as exemplified at Point C in  FIGS. 1 a    and  20 , and its descriptions. 
     Attach or attachment refers to one or more items, mechanisms, objects, things, structures or the like which are joined, fastened, secured, affixed or connected to another item, or the like in a permanent, removable, secured or non-permanent manner. For example, a tile hook may be attached to a support structure, such as a roof, as exemplified at tile hook  84  in  FIG. 1 a   , and its descriptions. As another example, a PV module may be attached to a support span as exemplified at cam foot  101  in  FIG. 3  and its descriptions. 
     Auto-grounding or automatic grounding refers to electrically connecting a device, equipment, chassis, frame, or the like to a metal structure or earth in a manner essentially independent of external influence or control, or working by itself with little or no direct human control, or happening automatically when another operation is performed for ensuring a common electrical potential; in some situations being connected to the Earth or a large mass of conductive material may provide a position of zero potential. One such automatic grounding device is exemplified as pin  115  in  FIG. 6 b   , and its descriptions. 
     Axis of rotation refers to a center around which something rotates, sometimes considered a straight line through all fixed points of a rotating rigid body around which all other points of the body move in a circular manner. Some exemplar axis of rotations for coupling portions are exemplified at Point A in  FIG. 3 , along with related descriptions. 
     Bracket refers to a simple, essentially rigid structure in the general shape of an L, one arm of which extends approximately 70-110 (often close to 90) degrees from the other arm. A Bracket is often an overhanging member that projects from a structure (such as a portion of a wall or frame) and may be designed to support a load with a vertical component, such as a skirt. A bracket may also refer to a fixture projecting from a wall, column, frame or the like which may be used for holding, securing, positioning or supporting another object. One such bracket attaching a groove to a support span is exemplified as cam foot  101  in  FIG. 3 , and its descriptions. As another example, a bracket attaching a PV module to a support span is exemplified as cam foot  101  in  FIG. 11 a   , and its descriptions. 
     Connect or connecting refers to loosely, slidably, or rigidly bringing together or into contact with or joining or fastening to form a link or association between two or more items, mechanisms, objects, things, structures or the like. For example, a spanner bar connected to another spanner bar may be exemplified at splice  118  in  FIG. 9 a   , and its descriptions. For another example, a spanner bar connected to a groove in a PV module frame may be exemplified at cam foot  101  in  FIG. 11 b   , and its descriptions. For an additional example, a spanner bar connected to a tile hook may be exemplified at clamp  103  in  FIG. 8 , and its descriptions. 
     Connector refers to an object, item, mechanism, apparatus, combination, feature, link or the like that loosely, slidable, or rigidly links, interlocks, joins, unites or fastens two or more things together. May also include a device, an object, item, mechanism, apparatus, combination, feature, link or the like for keeping two parts of an electric or electronic circuit in contact. For example, a connector for connecting or coupling the end of one rail to an end of another rail may be exemplified at splice  118  in  FIG. 9 a    and its descriptions. 
     Couple refers to loosely, slidably, or rigidly joining, linking, interlocking, connecting or mating two or more objects or items, mechanisms, objects, things, structures or the like together. For example, two modules may be coupled together, as exemplified at interlock  45  in  FIG. 30 , and its descriptions. 
     Coupling refers to an object, item, mechanism, apparatus, combination, feature, link or the like that loosely, slidably, or rigidly joins, links, mates, interlocks, or connects two things together. For example, a two rails may be coupled together by a coupling device, as exemplified at interlock  45  in  FIG. 30 , and its descriptions. 
     Double male connector refers to a connector (see above) having two male or insertable members, usually used for connecting two female or receiving parts or coupling members together. An example double male connector may be exemplified at splice  118  in  FIG. 9 a   , and its descriptions. 
     Disengage refers to detaching, freeing, loosening, extricating, separating or releasing from something that holds-fast, connects, couples or entangles. See Engagement below. 
     End refers to a final part, termination, extent or extremity of an object, item, mechanism, apparatus, combination, feature, or the like that has a length. For example, an end of a rail may be exemplified at Location E in  FIG. 7 a   , and its descriptions. 
     Engage refers to interlocking or meshing or more items, mechanisms, objects, things, structures or the like. See Disengage above. 
     Frame refers to an essentially rigid structure that surrounds or encloses a periphery of an item, object, mechanism, apparatus, combination, feature, or the like. For example, a PV module may have a frame around its edges as exemplified at frame  23  in  FIG. 3 , and its descriptions. 
     Freely refers to being without or exempt from substantial restriction or interference by a given condition or circumstance. May also refer to being unobstructed, unconstrained, unrestricted or not being subject to external restraint. For example, double male connector which is locked to a rail and freely insertable into another rail may be exemplified at Location F in  FIG. 9 a   , and its descriptions. 
     Groove refers to a long, narrow cut, rut, indentation, channel, furrow, gutter, slot or depression often used to guide motion or receive a corresponding ridge or tongue. Some grooves in the frame wall of a PV module are exemplified at Area G in  FIG. 2 , and its descriptions. 
     Height adjustable refers to change or adapt to bring items, objects, mechanisms, apparatus, combinations, features, components or the like into a proper, desired or preferred relationship of a distance or elevation above a recognized level, such as the ground or a support surface. Some height adjustable devices are exemplified at Area H in  FIG. 5 , and its descriptions. 
     Insertable refers to an object, item, mechanism, apparatus, combination, feature, link or the like which is capable of being put in, entered into, set within, introduced, inset, inserted, placed, fit or thrust into another an object, item, mechanism, apparatus, combination, feature, link or the like. An example double male connector which may be insertable into a support span is exemplified at splice  118  in  FIG. 9 a   , and its descriptions. 
     Integer multiple refers to a product of any quantity and a member of the set of positive whole numbers {1, 2, 3, . . . }. An integer multiple of a width of said PV module may actually be somewhat longer or shorter than the absolute width of the PV module, so as to permit or facilitate connection to a PV module, as by attachment to one or more frame members of a PV module, as may be exemplified at Area I in  FIG. 1 a   , and its descriptions. 
     Integral with refers to being essential or necessary for completeness, constituent, completing, containing, entire, or forming a unit. May also refer to consisting or composed of parts that together constitute a whole. An example frame integral with &amp; supporting a PV laminate is exemplified at frame  23  in  FIG. 3 , and its descriptions. 
     Length refers to the measurement or extent of an object, item, mechanism, apparatus, combination, feature, link or the like from end to end, usually along the greater or longer of the two or three dimensions of the body; in distinction from breadth or width. An example of a length of a spanner bar is exemplified at Notation L in  FIG. 8 , and its descriptions. 
     Locked refers to fastened, secured or interlocked. An example double male connector locked to a support span may be exemplified at Location K in  FIG. 9 c   , and its descriptions. 
     Orthogonally refers to relating to or composed of right angles, perpendicular or having perpendicular slopes or tangents at a point of intersection. An example spanner bar orthogonally connected to one of various locations along a PV module frame is exemplified at cam foot  101  in  FIG. 3 , and its descriptions. 
     Perimeter refers to an essentially continuous line forming the boundary, periphery or circuit of a closed geometric figure; the outer limits of an area. An example perimeter of a PV laminate surrounded by a frame is exemplified at frame  23  in  FIG. 1 a   , and its descriptions. 
     Pivotally refers to or relates to an object, item, mechanism, apparatus, combination, feature, link or the like serving as a pivot or the central point, pin, shaft or contact on which another object, item, mechanism, apparatus, combination, feature, link or the like turns, swings, rotates or oscillates. An example spanner bar pivotally connected to a PV module frame is exemplified at spanner bar coupling  302  in  FIG. 23 , and its descriptions. 
     Positionable refers to an object, item, mechanism, apparatus, combination, feature, link or the like which is capable of being positioned, placed or arranged in a particular place or way. An example of rails which are independently positionable relative to a PV module are exemplified at span bar  102  in  FIG. 3 , and their descriptions. 
     PV laminate refers to a photovoltaic device having an interconnected assembly of solar cells, also known as photovoltaic cells which is frequently, but not always, laminated with glass and/or other materials. A PV laminate with an integral frame which may support the PV laminate is sometimes referred to as a PV module (see below). An example PV laminate is exemplified at laminate  300  in  FIG. 1 a   , and its descriptions. 
     PV module refers to a photovoltaic module (sometimes referred to as a solar panel or photovoltaic panel) is a packaged interconnected assembly of solar cells, also known as photovoltaic cells, frequently, but not always, laminated with glass and other materials and sometimes surrounded by a frame. A plurality of PV modules are commonly used to form a larger photovoltaic system referred to as a PV array (see below), to provide electricity for commercial, industrial and residential applications. An example PV module is exemplified at module  10  in  FIG. 1 a   , and its descriptions. 
     PV array refers to s plurality of photovoltaic modules (see above) connected together often in a pattern of rows and columns with module sides placed close to or touching other modules. An example PV array is exemplified at array  81  in  FIG. 1 a   , and its descriptions. 
     Quarter turn or ¼ turn refers to an angle of rotation of an object, item, mechanism, apparatus, combination, feature, link or the like which is usually measured in degrees or radians having a range of between approximately 70 to 110 degrees, or sometimes between 80 to 100 degrees. An example of a coupling receiving a ¼ turn when connecting to a rail is shown or described at cam foot  101  in  FIG. 3 , and its descriptions. 
     Rail refers to refers to a relatively straight, usually essentially evenly shaped along its length, rod, beam, girder, profile or structural member or the like, or plurality of such, of essentially rigid material used as a fastener, support, barrier, or structural or mechanical member. For example, a two rails coupled together by a coupling device are exemplified at span bar  102  in  FIG. 23 , and its descriptions. 
     Removeable refers to one or more items, mechanisms, objects, things, structures or the like which are capable of being removed, detached, dismounted from or taken-away from another item or the like, or combination. 
     Rectilinear refers to one or more items, mechanisms, objects, things, structures or the like which are essentially bounded by, characterized by or forming straight and substantially parallel lines. An example rectilinear double male connector may be exemplified at splice  118  in  FIG. 9 a   , and its descriptions. 
     Rigidly couples refers to joining, linking, connecting or mating two or more objects or items, mechanisms, objects, things, components, structures or the like together in a non-flexible manner that is difficult to bend or be forced out of shape. For example, two span bars may be rigidly coupled together, as exemplified at splice  118  in  FIG. 9 a   , and its descriptions. 
     Roof refers to a structure or protective covering that covers or forms the upper covering or top of a building. The upper surface of a roof is often used as a support surface for mounting, connecting or otherwise attaching a PV module or a PV array. For example, some roofs are exemplified at Roof  83  in  FIG. 1 a   , and its descriptions. 
     Rotatably refers to one or more items, mechanisms, objects, things, structures or the like which are capable of being rotated, revolved or turned around or about an axis or center. For example, a portion of a coupling adapted to rotatably engage a PV module is exemplified at coupling  107  in  FIG. 3 , and its descriptions. 
     Skirt refers to an edging, molding or covering that may be fixed to the edge of a PV module to conceal or block the bottom area under a PV array when the PV array is mounted to a support surface. Some skirts are exemplified at skirt  104  in  FIG. 10 a   , and its descriptions. 
     Span refers to an extent or measure of space between, or the distance between two points or extremities. For example, a spanner bar which solely spans a width of a PV module is exemplified at span bar  102  in  FIG. 10 a   , and its descriptions. 
     Spanner bar refers to a relatively straight, usually evenly shaped along its length, rod, beam, girder, profile or structural member of essentially rigid material used as a fastener, support, barrier, or structural or mechanical member which spans a distance between an edge of a PV module and an attachment device, such as a tile hook, stand-off, hanger bolt or the like. For example, a spanner bar which spans a width of a PV module is exemplified at span bar  102  in  FIG. 10 a   , and its descriptions. 
     Support or supporting refers to one or more items, mechanisms, objects, things, structures or the like which are capable of bearing weight or other force, often to keep the item or the like from falling, sinking, slipping or otherwise moving out of a position. For example, a frame which is shown as integral with and supporting a PV laminate is exemplified at frame  23  in  FIG. 2 , and its descriptions. 
     Support structure refers to a structure, such as a roof, table or the ground which may provide a base for securing PV modules to form a PV array. Some support surfaces are exemplified at roof  83  in  FIG. 1 a   , and its descriptions. 
     Threaded refers to one or more items, mechanisms, objects, things, structures or the like which have, embody or include an essentially helical or spiral ridge or rib, as on a screw, nut, or bolt. An example of a threaded adjustment member for varying distance between a point on module and a rail may be exemplified at threaded stud  113  in  FIG. 5 , and its descriptions. 
     Various locations refers to places, positions or sites that are different from one another, more than one, individual or separate. For example, a spanner bar which may connect at various locations along a frame of a PV module is exemplified at span bar  102  in  FIG. 3 , and its descriptions. 
     Vertical height adjustment refers to change or adapt to bring items, mechanisms, objects, things, components, structures or the like or components into a proper, desired or preferred relationship of a distance or elevation above a recognized level, such as the ground or a support surface. Some vertical height adjustment devices are exemplified at Area J in  FIG. 5 , and its descriptions. 
     Width refers to the state, quality, or fact of being wide or a measurement or extent of something from side to side; in distinction from breadth or length. For example, a spanner bar which spans a width of a PV module is exemplified at span bar  102  in  FIG. 3 , and its descriptions. 
     Referring now to  FIG. 1A , there is shown a perspective view of a PV array including a plurality of PV modules  100  laid out in an x-y reference plane on a roof or support structure  81  such as a roof. PV modules  100  are shown in various Figs. with an integral frame  23  and as being faced with clear glass instead of a typical PV laminate with encapsulated PV cells in order to enable a view beneath PV modules  100  that reveals the mounting system hardware. One skilled in the art will recognize that PV modules  100  may comprise various types and numbers of PV cells.  FIG. 1A  also shows typical roofing tiles, such as tiles  82  and typical batons such as batons  83 . Other types and forms of batons and tiles are hereby expressly contemplated, such as roofing materials that are flat tiles, rolled-on or other flat or shaped materials. Various tiles  82  are shown in the Figs. only partially covering support structure  81  in order to enable a more complete view of support structure  81  and hardware beneath tiles  82 . Support structure  81  is herein shown as including a generally planar surface, however it may be a structure with thickness, width, depth, length and/or other dimension(s). In reference to any appropriate mounting structure, such as support structure  81 , the height adjustment of a coupling described hereinafter is considered relative to any essential surface or essential plane, such as a top surface. For ease of understanding this embodiment, a y-direction corresponds to the north-south dimension of the array, and an x-direction corresponds to the east-west direction. In the embodiment of  FIG. 1A , the reference plane is effected as being coextensive with a surface of various PV modules  10 , when PV modules  100  are positioned in their final installed positions. However, in further and various other embodiments, some of which are illustrated below, a reference plane may be above an upper surface of PV modules  10 , or below the lower surfaces of PV modules  100 . 
     A PV array  80  may be assembled together and attached to support structure  81  as by means of a discrete attachment point mounting system, which may comprise any or many of: cam feet, spanner bars, array skirts, double-tongue feet, brackets, feet, leveling feet, interlocks, parallel couplings, double-key couplings, key couplings and/or the like, some of which are explained in more detail below. Other components may be coupled to array  80  such as for example a grounding coupling, also further explained below. The PV array  80  of  FIG. 1A  is shown by way of example only. It is understood that PV array  80  may have more or less PV modules  100 , such as in the x and/or y direction. In the embodiment shown in  FIG. 1A , the support structure  81  may be a roof, such as a slanted roof of a residential dwelling or the like. However, it is understood that the PV array  80  may be supported on a wide variety of other support surfaces, such as for example a flat roof, a ground-mounted structure, a vertical support structure, or other structures which are understood by one of skill in the art. The defined x-y reference plane for the PV array  80  is substantially parallel to support structure  81 , and may be oriented in any of a wide variety of angles from horizontal to vertical. In other embodiments an x-y reference plane may be at an angle to support structure  81 . 
       FIG. 1A  further shows a series of tile hooks  84  attached to rafters  85  in any usual manner, such as with a lag screw (not shown) or the like. Tiles  82  are connected to battens  83  in any reasonable or usual manner. As seen on the right side of  FIG. 1A , tile hooks  84  may slip between tiles  82  at approximately the low point of curved tile  82  profile. The exposed y-axis length, commonly referred to as a “reveal”, of one or more tiles  82  may set a distance A between available discrete attachment points in the y-axis; and rafter location may set a distance B between available discrete attachment points along the x-axis. Therefore PV array  80  may be said to comprise discrete, rather than continuous, attachment points. 
       FIG. 1B  shows PV array  80  from a perspective up-roof from PV array  80  and shows an installed interlocking device, such as interlock  95 , which may provide a structural and ground bond connection between PV modules  100  at PV module  100  corner locations. Interlocks are discussed in further detail below. 
       FIG. 1C  shows interlock  95  which provides both X and Y axis structural and ground bond connections. Interlock  95  may be installed by inserting into frame grooves  11 A and rotating frame coupling components  45 A roughly 90 degrees. It is specifically contemplated that interlock  95  may be made of aluminum and steel, but other reasonably rigid materials, such as other metals or plastics, may be suitable as well. 
       FIG. 2  shows a side view of a photovoltaic module, such as PV module  100 . As shown, attached to PV module  100  is a connector, such as a cam foot  101 . As will be discussed in more detail below, cam foot  101  pivots into a groove of a PV module  100  frame  23 , such as frame groove  105 . Cam foot  101  is also connected, as by a cam nut  111 , to an underlying support, such as a spanner bar  102 , as discussed in greater detail below. As described in more detail below, cam foot  101  may also be connected to a skirt or other visual blocking or fire limiting device, such as an array skirt  104 , and may connect array skirt  104  to PV module  100 . Spanner Bar  102  may be coupled or otherwise connected to adjacent Spanner Bar  102   a , as by way of a press-fit, slip fit, or other connection as discussed further below. Spanner Bar  102  may also be inserted through a clamp, such as bar clamp  103 , as shown in  FIG. 2 , the function of which will be described further below. It is specifically contemplated that frame  23  of PV module  100  may be made of aluminum, but other reasonably rigid materials, such as other metals or plastics, may be suitable as well. It is also contemplated that cam foot  101 , spanner bar  102 , bar clamp  103 , and array skirt  104  may be made of aluminum, steel, or a combination thereof, but other reasonably rigid materials, such as other metals or plastics, may be suitable as well. 
       FIG. 3  shows cam foot  101  with a short tongue side, such as short tongue side  106 , and a long tongue side, such as long tongue side  107 . Also shown is a hump on the lower side of short tongue side  106 , such as hump  108 . Short side tongue  106  of cam foot  101  is shown connecting to a frame groove, such as frame groove  105  by means or way of a pivot-fit. A fully engaged home position of cam foot  101  may be defined by a slight rise  131  in the curved portion of hump  108 . Slight rise  131  may provide resistance to forces that would tend to rotate cam foot  101  back out of engagement with frame  23 . In the shown embodiment of  FIG. 3 , installation may be tool-free, that is, installation of PV array  80  of PV modules  100  may be effected without using mechanical or electrical tools. The installation of cam foot  101  into frame groove  105  provides a rapid, tool-free (in some embodiments), auto-grounding (in some embodiments), means or system for adjustably connecting cam foot  101  to PV module  100 . Cam foot  101  is adjustable in the x-axis as by variably attaching to frame groove  105  to line up with rafter  85  or location of attachment, such as a tile hook, as further described below. As described below, cam foot  101  may further provide pivot-fit or drop-in connections to up-roof modules. In other embodiments, cam foot  101  may connect to frame groove  105  via a ¼ turn key-in and may require a tool. Other embodiments discussed below may also provide auto-grounding connections; for example whereby a stainless steel pin (not shown here) in short tongue side  106  may pierce frame  23  to create a ground bond connection. 
       FIG. 4  shows a cross-sectional view of spanner bar  102  and a groove feature such as spanner groove  109 . Spanner groove  109  may comprise upper key slots  142 ,  143 , lower key slots  144 ,  145 , and lips  146 ,  147 . In some embodiments a shape of an upper portion of spanner groove  109  may be substantially similar to a shape of frame groove  105 , thereby enabling compatible equipment, such as such as spring clips for retaining wires, snap-in electrical boxes, PV module electronic devices, and so on, to be capable of connecting to both frame groove  105  and spanner groove  109 . 
       FIG. 5  shows cam foot  101  installed in spanner groove  109 . Also shown are various sub-components of cam foot  101 . A cup point or cone point bonding feature may be provided, such as cone point  110 , which is shown in  FIG. 5  as contacting a bottom surface of spanner groove  109 . The connection between cone point  110  and spanner groove  109  may be accomplished by compression (see below) which causes cone point  110  to cut into spanner bar  102  to create a ground bond connection. A cam nut, such as cam nut  111 , is shown partially inserted into spanner groove  109 . A camming surface, such as camming surface  112 , is shown engaged in spanner groove  109 . Cam nut  111  and camming surface  112  will be described in more detail below. A threaded stud, such as stud  113 , may be rotatably captured by cam nut  111  at a first end and threaded into coupling such as double tongue coupling  114  at a second end. Stud  113  causes coupling  114  to fall and rise in the z-axis when stud  113  is rotated clockwise and counter-clockwise respectively. In another embodiment (not shown), the direction of rotation of stud  113  will cause coupling  114  to rise and fall when stud  113  is rotated clockwise and counter-clockwise respectively. Such rotation may provide a simple mechanism to enable rapid height adjustment of PV module  100 , and other height adjustment mechanisms, such as ratchets or other devices, are hereby expressly contemplated. 
       FIG. 6 a    and  FIG. 6 b    show another embodiment whereby a metal pin, such as pin  115 , may be installed in short tongue side  106  of cam foot  101  and may create a ground bond connection between coupling  114  and PV module  100  groove  105  by cutting into module groove  105 .  FIG. 6 a    shows pin  115  protruding from a bottom side of short tongue  106 ; and  FIG. 6 b    shows pin  115  protruding from a top side of short tongue  106 . In other embodiments pin  115  only protrudes from either the top or bottom of short tongue  106 . In combination with the grounding action of cone point  110  (see above), the grounding action of pin  115  may create a reliable grounding path from spanner bar  102  to module frame  105 . 
       FIG. 7 a    shows cam foot  101  inserted into spanner groove  109 .  FIG. 7 b    shows cam foot  101  fully engaged with spanner groove  109  and with cam nut  111  rotated approximately 90 degrees (for example, from between 50 to 130 degrees, or 60 to 120 degrees, or 70 to 110 degrees) from its position in  FIG. 7 a   . When cam nut  111  is rotated approximately 90 degrees from its position in  FIG. 7 a   , camming surface  112  may press against and spread spanner groove  109 . This action may be complemented by lower key  138  on cam nut  111  jamming into lower key slots  144 ,  145  and cone point  110  cutting into spanner bar  102  to form a substantially rigid connection between cam nut  111  and spanner bar  102 . This connection arrangement may provide a rapid, auto-grounding connection that may require less than 360.degree. of rotation, such as approximately 90.degree., with between 70.degree. to 110.degree. of rotation (see description above), and may provide adjustability in the y-axis since cam foot  101  may be able to be connected to spanner bar  102  at essentially any point substantially along its whole length. In other embodiments the orientation of spanner bars is rotated 90.degree. from the orientation of  FIG. 1 , thereby enabling cam foot  101  to spanner bar  102  connections substantially anywhere along the x-axis of PV array  80 . In another embodiment, cam nut  111  may comprise a camming surface that expands against other surfaces of spanner groove  109 , such as upper key slots  142 ,  143 , lower key slots  144 ,  145  or other walls of spanner groove  109 . 
       FIG. 8  shows bar clamp  103  connected to a tile hook, such as tile hook  116 . In other embodiments, bar clamp  103  may be connected to other types of tile hooks or other components such as stand-offs, stanchions, threaded rods, and/or the like. Bar clamp  103  may be connected to tile hook  116  via a carriage bolt  103   a  and nut (not shown). In other embodiments, bar clamp  103  may be connected as by other fastener types such as snap-in, press-fit, cam lock, or other mechanical connections known in the art.  FIG. 8  also shows surface  117  of bar clamp  103 . Surface  117  may, in various embodiments, be oriented perpendicular or in other manner to its orientation as shown in  FIG. 8 . For example, tile hook  116  may be replaced by a tile hook with a substantially flat plate top surface, instead of a vertical wall as shown in  FIG. 8 , and bar clamp  103  may be rotated approximately 90.degree. counter-clockwise to connect to it. The variable orientations in which bar clamp  103  may be installed, may allow it to be mated with a wide variety of roof tile hooks and other roof attachment types or mechanisms. The connection of bar clamp  103  to tile hook  116  or other attachment hardware types as described above, may provide simple and rapid means for connecting bar clamp  103  to standard roof attachment systems such as tile hooks, stand-offs, stanchions, threaded rods, and others which are common or known in the art. 
       FIG. 8  also shows bar clamp  103  connected to spanner bar  102 . Spanner bar  102  may be inserted through bar clamp  103  as shown. The connection between spanner bar  102  and bar clamp  103  may be made via a wrap-around friction connection, whereby a bolt  103   a  may deform the approximately square shape of bar clamp  103  as it may be tightened around approximately square spanner bar  102 . In other embodiments, other connection types such as snap-in, press-fit, cam lock, and other mechanical connections known in the art may be used. Some embodiments may provide dimples (not shown) on bar clamp  103  to ensure proper angular alignment with x-y reference plane. The connection between spanner bar  102  and bar clamp  103  may provide a means for rapid and rigid connection of these components. 
       FIG. 9 a    shows spanner bars  102  and  102   a  and a splicing device, such as double male connector  118 , which is installed at one end of spanner bar  102 .  FIG. 9 b    illustrates how spanner bar  102  and spanner bar  102   a  may be coupled together by pressing end  119  of spanner bar  102   a  onto double male connector  118 . This connection may be accomplished by means of an interference or press fit but may, in other embodiments, be accomplished by a slip-fit, bolted connection or the like. 
       FIG. 9 e    shows spanner bar  102  with one double male connector  118  removed. Double male connector  118  may have two male or insertable members for inserting into female portions near or at the ends of spanner bars  102 . Double male connector  118  as shown in  FIG. 9 e    may comprise a resilient rubber or spring material  318   b  covered by a protective layer (not shown). Spring material  318   b  may help to take up dimensional variations in the materials utilized and/or prevent rattle. Protective cover may help to prevent damage to spring material  318   b  during insertion. Double male connector  118  may also comprise a substantially rectilinear shape along its length that is primarily characterized by straight and substantially parallel lines. Other embodiments contemplate chamfered or tapered forms. Approximately half of a length of double male connector  118  may be inserted into spanner bar  102 . The remaining approximately half of double male connector  118  may be inserted into spanner bar  102   a . While spanner bar  102  comprises 2 double male connectors  118 , other embodiments (whether shown or not shown herein) comprise spanner bars with only one double male connector  118 . 
     As shown in  FIGS. 10 a  and 10 b   , array skirt  104  may be connected to cam foot  101  for rapid, snap-on installation. FIG.  1 A 0   a  shows a groove, such as skirt groove  121 , placed onto short tongue side  106  of cam foot  101 . FIG.  1 A 0   b  shows the final position of installed array skirt  104 .  FIGS. 10 a  and 10 b    illustrate a method of installation, whereby array skirt  104  may be pivoted downward from the position illustrated in  FIG. 10 a    to the position illustrated in  FIG. 10 b   . When in the fully engaged position, as shown in  FIG. 10 b   , a lip of skirt groove snaps into recess formed by slight rise  131  on lower side of short tongue  106  (as discussed above). In the embodiment shown in  FIGS. 10 a  and 10 b   , installation may be tool-free. The installation of cam foot  101  into frame groove  105  may provide a rapid, tool-free (in some embodiments), auto-grounding (in some embodiments), means and method for adjustably connecting cam foot  101  to array skirt  104 . In still other embodiments coupling  114  may further comprise a lock or an anti-rotation component which may be inserted full skirt engagement in order to resist disengagement of skirt  104 . 
       FIG. 11 a    and  FIG. 11 b    show a pivot-fit method of installation whereby frame groove  105  may be placed on long tongue side  107  of cam foot  101  at a first angle of approximately 15-60 degrees (as in  FIG. 11 a   ) and rotated downward to a second angle of approximately 0.degree. (as in  FIG. 11 b   ). Offset bearing points in frame groove  105  may allow insertion of long tongue into frame groove  105  at the first angle, then restrict movement in the z-axis between frame groove  105  and long tongue  107  at the second angle. Long tongue may be inserted into frame groove  105  to various depths in order to align PV module  100  with adjacent PV modules  100  (not shown). This installation method may offer rapid, tool-free (in some embodiments), auto-grounding (in some embodiments), means and method for adjustably connecting PV module  100  to cam foot  101 . This installation method may allow adjustability in the x-axis by variably positioning PV module  100  onto cam foot  101  to line up with roof rafters or a location of attachment means, such as tile hook  116  described further above and below. 
       FIGS. 12 through 17  show a method of installing a PV array such as PV array  80  shown in  FIG. 1A . In such a method, PV modules  100  (similar to PV modules  100  shown in  FIG. 2 ) may be installed on tile roofs  81  using the following set of procedures:
         1. Place tile hooks  84  at pre-determined north-south (N-S) and east-west (E-W) locations, as shown. These locations may be determined by referencing load tables (such as incorporated herein by reference) that present calculated N-S and E-W spacing based on inputs such as average wind speed, wind category, roof slope and snow load (see especially  FIG. 12 ).   2. Attach first row of spanner bars  102  to tile hooks  84  by slipping bar clamp  103  over front row spanner bar  102 , aligning tile hook slot  84 A with a slot  123  in bar clamp  103 , and using a bolt  103   a  and nut (not shown) or other common fasteners (see especially  FIG. 13 ).   3. Attach second row of spanner bars  102  (see especially  FIG. 14 ) by inserting spanner bar double male connector  118  into female end of spanner bar  102   a . (see especially  FIGS. 9 a , 9 b   ) Attach spanner bar  102  to a second row of tile hooks  84  (see especially  FIG. 14 ) by once again slipping bar clamp  103  over spanner bar  102  and aligning tile hook slot  122  with spanner bar clamp slot  123  and using a bolt  103   a  and nut (not shown) or other common fasteners (see especially  FIG. 8 ).   4. Attach cam foot  101  to spanner bar  102  located on the front row by inserting cam nut  111  into spanner groove  109  (see especially  FIG. 8 a   ) and rotating cam nut  111  a quarter turn within spanner groove  109  to widen groove  109  and create a spring force lock onto cam nut  111  (see especially  FIG. 8 b   ).   5. Attach remaining rows of spanner bars  102  by again inserting spanner bar double male connectors  118  and attaching spanner bars  102  as previously described (see especially  FIG. 15 ).   6. Once all spanner bars  102  have been attached in place (see especially  FIG. 16 ), install array skirt  104  (similar to skirt  104  in  FIG. 16 ) to the front row of cam foot  101  (see especially  FIGS. 10 a , 10 b   ).   7. Install first row of PV modules  100  (similar to PV modules  100  shown in  FIG. 2 ) onto cam foot  101  (see especially  FIGS. 11 a , 11 b   ). Connection of PV module  100  to cam foot  101  may create a continuous ground path from frame groove  105  to cam foot  101  and thus to the spanner bar  102  (see especially  FIG. 11 b   ).   8. Ensure PV modules  100 , (similar to PV modules  100  in  FIG. 2 ) are essentially level to each other and parallel to the rooftop  81 . If they are sufficiently out of alignment, rotate threaded studs  113  in cam foot  101 , to raise or lower appropriate PV module edges.   9. Install the next row of PV modules  100  (similar to PV modules  100  in  FIG. 2 ) by first attaching cam foot  101  to frame groove  105  (see especially  FIG. 28 ), and then attaching cam foot  101  (see especially  FIG. 3 ) to spanner groove  109  (see especially  FIG. 4 ).   10. Repeat these procedures until entire PV array  80  is installed and level. (see especially  FIG. 1A )       

       FIGS. 12 through 17  show a method of installing a PV array such as PV array  80  shown in  FIG. 1A . In such a method, PV modules  100  (similar to PV modules  100  shown in  FIG. 2 ) In other embodiments spanner bars  102  may be run horizontally instead of vertically on the roof and in still other embodiments PV modules  100  (similar to PV modules  100  in  FIG. 2 ) may be oriented in portrait orientation instead of landscape as shown. Other and similar arrangements are explicitly considered, including PV modules not being oriented in a N-S or E-W plan. 
       FIG. 18  shows an embodiment of a spanner bar, such as spanner bar  202 . Spanner bar  202  may be similar to spanner bar  102  except that double male connector  118  is replaced by a necked down portion  218  of spanner bar  202  and there is no spanner groove  109 . Necked down portion  218  may fit into a female portion  203  at an opposite end from necked down portion  218 . Thus, spanner bar  202  may comprise a one-piece construction with one male end and one female end. Spanner bars  202  may be capable of mating end-to-end, in a manner similar to conventional tent poles. One skilled in the art will recognize that spanner bar  202  may comprise an inside diameter sized to fit bar clamp  103  as discussed above. In some embodiments spanner bar  202  may comprise a spanner groove  109 . In embodiments where spanner bar  202  comprises a spanner groove  109 , spanner bar  202  may mate with cam foot  101  as described above for spanner bar  102 . In embodiments where spanner bar  202  does not comprise a spanner groove  109  (as depicted in  FIG. 18 ), spanner bar  202  may connect to PV module  100  by way of a typical square tube clamping mechanism as are known in the art. 
     One or more additional benefits that the above described hardware, systems and methods may facilitate include the following:
         May provide a system that simplifies the hardware and/or installation procedure required to mount PV modules on a support structure that requires discrete attachment points, such as a tile roof or ground mount structure;   May reduce or eliminate the need for long mounting rails beneath module arrays, thereby reducing problems associated with warehousing, shipping, and maneuvering long rails onto a roof;   May increase layout flexibility and simplify installations on complicated roofs that may have numerous smaller roof surfaces and/or numerous obstructions (such as vent pipes, chimneys, and so on) since rails may not need to be cut on site;   May enable more cost-effective mounting in landscape orientation since two rows of rail are not required for every row of PV modules as in conventional systems;   May reduce total part count and total number of fasteners required;   May improve the speed of installation and overall reliability of the PV array grounding system;   May provide greater integration with other required equipment in the overall PV system, such as electrical junction and combiner boxes, wire management devices, and other equipment since some embodiments provide mounting hardware that may utilize similar male and female mating parts as other equipment in the system;   May reduce a total length of spanner bar and/or rail material as compared to conventional systems due to optimization of structural support system;   May reduce a total number of attachment points as compared to conventional systems due to optimization of structural support system;   May enable faster PV array system installations due to the ability of a single installer to place and mount PV modules on support structure  81     May allow for easy on site changes to array layout when an actual rooftop does not accurately match the one used for a planned PV array system design;   May provide ability to adapt to uneven roof surfaces.       

       FIGS. 19 through 32  show an embodiment of a discrete attachment point mounting system. 
       FIG. 19  shows a spanner bar assembly  340  comprising a connector such as a spanner bar coupling  301 , a module spanning bar such as a spanner bar  302 , and a module spanning bar clamp such as a bar clamp  303  that may mount to tile hooks  350  or other common tile mount hardware, as with common fasteners such as bolts, nuts, and washers which may be fastened through holes or slots such as clamp holes  303 A and tile hook slot  350 A. Spanner bar  302  may span one or two PV modules  309 , but typically no more; as it may not be intended to replace a long rail which are commonly used in the art. Spanner bar  302  may be provided in lengths that are substantially close to one or two times the length or width of PV module  309  (herein referred generally referred to as “width”). Spanner bar  302  being relatively short and produced in a length that is essentially an integer multiple of the module dimension (noted as “width” above) may yield significant benefits in terms of ease of transport and speed of installation. In some embodiments spanner bar  302  may also provide a simple means to span from two PV module  309  frame  311  sides over to a tile hook  350 , thereby freeing up either the x or y axis for positioning flexibility on a roof  308 . In some embodiments spanner bar  302  spans the distance between frame  311  side on a first PV module  309  over to frame  311  side on an adjacent PV module  309 , while crossing under first PV module  309 . For example, an east frame  311  side on first PV module  311  may be effectively coupled to an east frame  311  side on second PV module  311  by way of spanner bar  302  and associated spanner bar couplings  301 . In still other embodiments spanner bar  302  spans between two parallel frame sides of PV module  309 . 
     Clamp holes  303 A may be in various quantities and may be round, oval, slotted, or the like. As shown in more detail below, spanner bar coupling  301  may connect to spanner bar  302  via a nut  380  that locks in a groove such as spanner groove  302 A within the top surface  302 B of spanner bar  302  and a machine screw or bolt running through bar coupling  1  (not visible in this view). In other embodiments nut  380  and bolt are replaced by a quarter turn cam nut. 
     Bar clamp  302  may be connected to tile hook  350  via carriage bolt and nut. In other embodiments, bar clamp  2  may be connected via other fastener types, such as snap-in, press-fit, cam lock, and/or other mechanical connections known in the art.  FIG. 19  also shows surface  303 B of bar clamp  303 . Surface  303 B may, in other embodiments, be oriented perpendicular to its orientation as shown in  FIG. 19 . The variable orientations in which bar clamp  303  may be installed may allow it to be mated with a wide variety of roof tile hook and other roof attachment types. The connection of bar clamp  303  to tile hook  350  or other attachment hardware types as described above, may provide simple and rapid means for connecting bar clamp  303  to standard roof attachment systems such as tile hooks, stand-offs, stanchions, threaded rods, and/or others common in the art. 
       FIG. 19  also shows bar clamp  303  connected to spanner bar  302 . Spanner bar  302  may be inserted through bar clamp  303  as shown. The connection between spanner bar  302  and bar clamp  303  may be made as by a wrap-around friction connection, whereby a bolt may deform the approximately square shape of bar clamp  303  as it may be tightened around the approximately square spanner bar  302 . In other embodiments, other connection types such as snap-in, press-fit, cam lock, and/or other mechanical connections known in the art may be used. Some embodiments may provide dimples on bar clamp  303  to ensure proper angular alignment with a plane of the mounting surface. The connection between spanner bar  302  and bar clamp  303  may provide a means for rapid and rigid connection of these components. 
     It is contemplated that spanner bar assembly  340  comprises components made from aluminum, steel, or other hard metals, or plastic may be suitable as well. 
       FIG. 20  shows a photovoltaic module array such as PV array  330  mounted on a roof  308  with tile hooks  350  and spanner bar assemblies  340 . PV Array  330  comprises a plurality of photovoltaic modules such as PV module  309 . As in previous figures, a PV laminate is shown as clear glass so that components below may be viewed.  FIG. 20  also shows an interlocking device, such as interlock  345 , which may provide both structural and ground bond connections at the corners of PV modules  309 . Interlock  345  is described in more detail below. 
       FIG. 21  shows a portion of PV module  309 . As is common in the art, PV module  309  comprises a PV laminate  310  with an aluminum frame  311  to provide additional strength and a location for attachment of mounting hardware. Spanner bar assemblies  340  may be used with module frames that have a groove on the outer surface such as frame groove  311 A. Other embodiments comprise spanner bar assemblies optimized for use with non-grooved PV modules frames. In such embodiments, spanner bar coupling  301  may comprise a hold-down clamp or end clamp as are common in the art for non-grooved frame PV modules. 
       FIG. 21  also shows spanner bar coupling  301  connected to spanner bar  302  through the use of a bolt and nut  380  that interlocks with spanner groove  302 A. As with cam foot  101  in  FIG. 5 , spanner bar coupling  301  may contain a cup or cone point bonding feature such as cone point  110 . Spanner bar coupling  301  may be attached to module frame  311  using a geometrically compatible part feature  301 A that interlocks with the groove  311 A located on the outer surface of the module frame  311  by way of a rotational tool-free motion. In other embodiments a standard T nut may be used instead of cam nut  307 . 
       FIGS. 22 through 32  show the steps required for installing a photovoltaic array such as PV array  330 . 
     In  FIG. 22 , four typical tile hooks  350  are shown mounted to a rooftop surface. One familiar with the art may recognize that other tile roof mounting hardware besides tile hooks could be used for the same function. A frame mount component  314  that allows for a direct attachment to tile hooks through use of standard fasteners such as nuts, bolts washers and the like may be installed on the first row of tile hooks  350 .  FIG. 22  also shows the attachment of spanner bar  302  to tile hook  350  through the use of bar clamp  303 . 
       FIG. 23  shows a method of installing PV module  309  in its desired location upon a rooftop as by a pivot-fit, drop in action as discussed above. This method allows for rapid installation that does not require the use of tools, therefore saving installation time. 
       FIG. 24  shows spanner bar coupling  301  inserting into frame groove  311 A. Also depicted is the alignment of cam nut  307  with spanner groove  302 A. Once spanner bar coupling  301  has been rotationally engaged frame groove  311 A, nut  380  may be secured as described above. 
       FIGS. 25 through 27  show how additional spanner bar assemblies  340  may continue to be connected once the first PV module  309  has been installed. 
       FIG. 25  depicts spanner bar assembly  340  being installed as by connection to frame groove  311 A of PV module  309 . This connection may be accomplished via a drop-in, pivot-fit action and serves to lengthen the run of structural material, which spans between tile hooks  350 . 
       FIG. 26  shows a close up view of geometrically compatible part feature  301 A of spanner bar coupling  301  pivoting into frame groove  311 A in the direction of the arrow. 
       FIG. 27  shows spanner bar assembly  340  in its installed position on a rooftop. 
       FIG. 28  shows additional PV module  309  being installed via a drop-in, pivot-fit action as described and shown in  FIG. 23  above. 
       FIG. 29  shows additional PV module  309  in its installed position on a rooftop. 
       FIG. 30  shows installed interlock  345 . Interlock  345  may be installed by inserting into frame grooves  311 A and rotating frame coupling components  345 A approximately 90 degrees. Interlock  345  may provide structural and/or grounding connections between PV modules  309 . 
       FIG. 31  Shows a fully assembled PV array  390  (roof not shown). Note that spanner bars  302  may, in some cases, not be installed under each module. In this case interlock  345  provides the necessary structural connection between modules  309  to minimize or eliminate the need for spanner bar  302  underneath PV module  355 .  FIG. 31  shows an example  355  of a PV module  309  that does not have a spanner bar  302  underneath it. 
       FIG. 32  shows an alternate embodiment where spanner bars  302  are replaced by spanner bars  395  which span two modules  309  instead of one module  309 . 
     In other embodiments, spanner bars  302  may be run vertically instead of horizontally on a roof and in still other embodiments PV modules  309  may be oriented in landscape orientation, or other orientation, instead of portrait as shown. 
       FIGS. 33-47  show additional embodiments.  FIGS. 33-37  show an alternate double male coupling such as double male coupling  410 . Double male coupling may couple spanner bars  420 A and  420 B and may provide tapped holes  412 ,  414  for connection to a double tongue coupling  430 . Spring clip  415  may provide retention and grounding between components and may be secured to spanner bar  420 A. 
       FIGS. 38-44  an embodiment where a double male connector such as double male connector  510  comprises a channel-shaped member  525  for coupling adjacent spanner bars  520 A,  520 B and for connecting to double male PV module coupling  514 .  FIGS. 42-44  show an embodiment where double male module couplings  514  interlock PV modules  510  on a ground mount structure  540  and connect to double male connectors  525  which link to spanner bars  520 A,  520 B. Spanner bars  520 A,  520 B connect to discrete attachment points on mounting structure  540 . Interlocks  560  may comprise connections to double male connectors  525  in alternate embodiments instead of double tongue couplings  514 . 
     While a number of 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 be interpreted to include all such modifications, permutations, additions, and sub-combinations as are within their true spirit and scope.

Metadata:
Filing Date: 20180109
Publication Date: 20190604
Grant Date: 20190604
Priority Date: 20101213
Inventors: WEST, Jack Raymond
YOUMANS, DAVID
ATCHLEY, BRIAN
Assignee: APPLE INC
CPC Classifications: [{"code": "Y02B10/20", "inventive": false, "first": false, "tree": "[]"}, {"code": "F24S2025/801", "inventive": false, "first": false, "tree": "[]"}, {"code": "F24S25/632", "inventive": true, "first": false, "tree": "[]"}, {"code": "F24S25/70", "inventive": true, "first": true, "tree": "[]"}, {"code": "H02S20/23", "inventive": true, "first": false, "tree": "[]"}, {"code": "F24S25/65", "inventive": true, "first": false, "tree": "[]"}, {"code": "F24S25/613", "inventive": true, "first": false, "tree": "[]"}, {"code": "Y02E10/47", "inventive": false, "first": false, "tree": "[]"}, {"code": "F24S2025/807", "inventive": false, "first": false, "tree": "[]"}, {"code": "F24S25/33", "inventive": true, "first": false, "tree": "[]"}, {"code": "Y10T403/38", "inventive": false, "first": false, "tree": "[]"}, {"code": "F24S25/636", "inventive": true, "first": false, "tree": "[]"}, {"code": "Y02B10/12", "inventive": false, "first": false, "tree": "[]"}, {"code": "Y10T403/32975", "inventive": false, "first": false, "tree": "[]"}, {"code": "F24S25/613", "inventive": true, "first": false, "tree": "[]"}, {"code": "F24S25/33", "inventive": true, "first": false, "tree": "[]"}, {"code": "F24S25/613", "inventive": true, "first": false, "tree": "[]"}, {"code": "F24S25/632", "inventive": true, "first": false, "tree": "[]"}, {"code": "F24S2025/801", "inventive": false, "first": false, "tree": "[]"}, {"code": "F24S2025/807", "inventive": false, "first": false, "tree": "[]"}, {"code": "F24S25/636", "inventive": true, "first": false, "tree": "[]"}, {"code": "F24S25/65", "inventive": true, "first": false, "tree": "[]"}, {"code": "F24S25/70", "inventive": true, "first": true, "tree": "[]"}, {"code": "F24S25/33", "inventive": true, "first": false, "tree": "[]"}, {"code": "Y02E10/50", "inventive": false, "first": false, "tree": "[]"}, {"code": "F24S25/636", "inventive": true, "first": false, "tree": "[]"}, {"code": "Y02E10/47", "inventive": false, "first": false, "tree": "[]"}, {"code": "F24S2025/801", "inventive": false, "first": false, "tree": "[]"}, {"code": "Y10T403/38", "inventive": false, "first": false, "tree": "[]"}, {"code": "F24S25/70", "inventive": true, "first": true, "tree": "[]"}, {"code": "Y10T403/38", "inventive": false, "first": false, "tree": "[]"}, {"code": "Y02B10/10", "inventive": false, "first": false, "tree": "[]"}, {"code": "Y10T403/32975", "inventive": false, "first": false, "tree": "[]"}, {"code": "F24S25/632", "inventive": true, "first": false, "tree": "[]"}, {"code": "Y02E10/47", "inventive": false, "first": false, "tree": "[]"}, {"code": "Y10T403/32975", "inventive": false, "first": false, "tree": "[]"}, {"code": "Y02B10/20", "inventive": false, "first": false, "tree": "[]"}, {"code": "Y02B10/20", "inventive": false, "first": false, "tree": "[]"}, {"code": "Y02B10/10", "inventive": false, "first": false, "tree": "[]"}, {"code": "F24S25/65", "inventive": true, "first": false, "tree": "[]"}, {"code": "H02S20/23", "inventive": true, "first": false, "tree": "[]"}, {"code": "H02S20/23", "inventive": true, "first": false, "tree": "[]"}, {"code": "F24S2025/807", "inventive": false, "first": false, "tree": "[]"}]
Family ID: 46232745