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

Abstract

A system and method are disclosed for quickly and easily assembling PV modules into a PV array in a sturdy and durable manner. In examples of the present technology, the system includes various couplings having a first engaging portion adapted to engage a first PV module and a second engaging portion adapted to engage a second PV module. At least one of the engaging portions allows variable positioning of the engaged PV module along the engaging portion.

What is claimed: 
     
         1 . A method of assembling a photovoltaic array, comprising:
 (a) placing a first photovoltaic leveling foot on a surface;   (b) affixing a first photovoltaic module to the first photovoltaic leveling foot by:
 (i) holding the first photovoltaic module at an angle to the surface, 
 (ii) connecting a lower side edge of the first photovoltaic module onto the first leveling foot, and then 
 (iii) pivoting the first photovoltaic module downwards by lowering an upper side edge of the first photovoltaic module such that the lower side edge of the first photovoltaic module pivot-locks onto the first leveling foot; and 
   (c) affixing a second photovoltaic leveling foot onto the upper side edge of the first photovoltaic module.   
     
     
         2 . The method of  claim 1 , wherein the first photovoltaic module is held at an angle from 10 to 20 degrees to the surface when connected onto the first leveling foot. 
     
     
         3 . The method of  claim 1 , wherein the first leveling foot has a key portion extending from one side and a tongue portion extending from an opposite side, and wherein the first photovoltaic module has a side groove on its lower side edge, and wherein the tongue portion on the first leveling foot is inserted into the side groove on the lower side edge of the first photovoltaic module prior to the first photovoltaic module being pivot-locked down onto the first leveling foot. 
     
     
         4 . The method of  claim 3 , wherein an outer portion of the side groove deforms when the first photovoltaic module is pivot-locked down onto the tongue of the first leveling foot. 
     
     
         5 . The method of  claim 3 , wherein the side groove comprises an upper bearing surface and a lower bearing surface and wherein the tongue of the first leveling foot pushes against the upper and lower bearing surfaces when the first photovoltaic module has been pivot-locked down onto the tongue of the first leveling foot. 
     
     
         6 . The method of  claim 1 , wherein the first photovoltaic module pivot-locks onto the first photovoltaic leveling foot when the first photovoltaic module is positioned parallel to the surface. 
     
     
         7 . The method of  claim 1 , wherein the surface is a roof surface. 
     
     
         8 . The method of  claim 3 , wherein an outer portion of the side groove is disposed at an angle to the first photovoltaic module, and wherein the tongue is placed into the side groove of the first photovoltaic module when the first photovoltaic module is disposed at an angle to the tongue of the first leveling foot prior to the first photovoltaic module being pivot locked onto the tongue of the first leveling foot. 
     
     
         9 . The method of  claim 3 , wherein the second photovoltaic leveling foot has a key portion extending from one side and a tongue portion extending from an opposite side, and wherein the key portion is inserted into a side groove on the upper side edge of the first photovoltaic module. 
     
     
         10 . The method of  claim 1 , wherein the first photovoltaic module is rotated downwardly from 10 to 20 degrees to pivot-lock onto the first leveling foot. 
     
     
         11 . The method of  claim 1 , further comprising:
 (d) placing the second photovoltaic leveling foot on the surface; and   (e) affixing a second photovoltaic module onto the second photovoltaic leveling foot by:
 (i) holding the second photovoltaic module at an angle to the surface, 
 (ii) connecting a lower side edge of the second photovoltaic module onto the second leveling foot, and then 
 (iii) pivoting the second photovoltaic module downwards by lowering an upper side edge of the second photovoltaic module such that the lower side edge of the second photovoltaic module pivot-locks onto the first leveling foot. 
   
     
     
         12 . The method of  claim 11 , wherein the second leveling foot has a key portion extending from one side and a tongue portion extending from an opposite side, and wherein the key portion firmly locks onto the first photovoltaic module, but wherein the tongue portion permits the second photovoltaic module to slide along the tongue in a direction parallel to the surface prior to the second photovoltaic module being pivot-locked onto the tongue portion of the second leveling foot. 
     
     
         13 . The method of  claim 1 , wherein the second photovoltaic leveling foot is affixed onto the first photovoltaic module before the first photovoltaic module is pivot-locked onto the first leveling foot. 
     
     
         14 . The method of  claim 1 , wherein the second photovoltaic leveling foot is affixed onto the first photovoltaic module after the first photovoltaic module is pivot-locked onto the first leveling foot. 
     
     
         15 . The method of  claim 11 , further comprising:
 (f) adjusting the height of the second leveling foot after the first and second photovoltaic modules have been attached thereto.