Solar mounting assemblies

Patent metadata

Field	Value
Publication number	US-11757399-B2
Application number	US-202117169046-A
Country	US
Kind code	B2
Filing date	Feb 5, 2021
Priority date	Aug 23, 2016
Publication date	Sep 12, 2023
Grant date	Sep 12, 2023

Abstract

A structural support block cooperates with a cone-shaped protrusion in a roof flashing. The support block and protrusion have a through-hole allowing a fastener to secure the support block and flashing to a roof. Cooperation of the support block and the cone-shaped protrusion in the roof flashing diverts water, particularly on sloped surfaces.

First claim

We claim:

1. A solar mounting assembly comprising:
a flashing comprising a substantially flat sheet, the flashing having an upward-facing tapered protrusion and a through-hole in a center of the tapered protrusion; and
a support block that is separate from the flashing, the support block being cast in a single piece and having:
a bracket having at least one grooved surface that is cast into the support block, the grooved surface configured to engage solar mounting accessories, and a longitudinal slot that is cast into the support block, the longitudinal slot configured to secure the solar mounting accessories to the support block;
a top surface integrated with the bracket;
an outer side surface on an up-slope portion of the support block, the outer side surface cast into the support block, the outer side surface forming an obtuse angle with the top surface;
an aperture that is cast into the support block, the aperture disposed through the top surface, wherein the aperture is configured to align with the through-hole in the center of the tapered protrusion; and
an internal cavity that is cast into the support block, wherein the internal cavity is configured to accommodate the tapered protrusion of the flashing when the support block is placed on the flashing over the tapered protrusion such that the support block compresses onto the flashing when a first fastener is inserted through the aperture and the through-hole, wherein the internal cavity includes a plurality of internal ribs configured to align with the tapered protrusion.

2. The solar mounting assembly of claim 1 , wherein the flashing further comprises a first notch feature configured as an alignment guide.

3. The solar mounting assembly of claim 1 , wherein the flashing further comprises a ridge feature configured to provide structural support when the first fastener is compressed over the tapered protrusion and the through-hole onto the flashing.

4. The solar mounting assembly of claim 1 , wherein the flashing is a substantially uniform thickness.

5. The solar mounting assembly of claim 1 , wherein a top of the tapered protrusion is flat and substantially parallel with the flashing.

6. The solar mounting assembly of claim 1 , wherein the bracket is configured in an asymmetrical orientation with the outer side surface on the up-slope portion and an elongated, substantially rectangular portion on a down-slope portion of the support block.

7. The solar mounting assembly of claim 1 , wherein the internal cavity includes a plurality of internal ribs configured to provide structural support for a cone-shaped attachment block.

8. The solar mounting assembly of claim 1 , wherein the first fastener is flanged.

9. The solar mounting assembly of claim 1 , wherein the first fastener has a cavity on an underside of a flange to accommodate a flexible washer, wherein the flexible washer is compressed between the flange and the support block when the solar mounting assembly is installed on an installation surface.

10. The solar mounting assembly of claim 1 , further comprising a substantially planar outer side surface on a down-slope portion of the support block, the substantially planar outer side surface forming an obtuse angle with the top surface.

11. The solar mounting assembly of claim 10 , wherein the support block further comprises:
a second substantially planar outer side surface that forms an obtuse angle with the top surface.

12. A solar mounting assembly comprising:
a support block cast in a single piece and having:
a bracket having at least one grooved surface that is cast into the support block, the grooved surface configured to engage solar mounting accessories, and a longitudinal slot that is cast into the support block, the longitudinal slot configured to secure the solar mounting accessories to the support block;
a top surface integrated with the bracket;
an outer side surface on an up-slope portion of the support block, the outer side surface cast into the support block, the outer side surface forming an obtuse angle with the top surface;
an aperture that is cast into the support block, the aperture disposed through the top surface, wherein the aperture is configured to align with a through-hole in a flashing, the flashing having an upward-facing tapered protrusion; and
an internal cavity that is cast into the support block, wherein the internal cavity includes a plurality of internal ribs configured to align with the tapered protrusion.

13. The solar mounting assembly of claim 12 , further comprising:
a cone-shaped attachment block, wherein the cone-shaped attachment block comprises:
a plurality of peripheral apertures configured to cooperate with second fasteners when the second fasteners are fastened into an installation surface; and
a central aperture, the central aperture having internal threads configured to cooperate with a first fastener passing through the aperture in the top surface of the support block.

14. The solar mounting assembly of claim 12 , wherein two opposing sides of the bracket taper toward each other in a direction away from the top surface.

15. The solar mounting assembly of claim 12 , wherein the bracket further comprises an inset recess on sides of the longitudinal slot.

16. The solar mounting assembly of claim 15 , wherein the inset recess is configured to accept a flange of a fastener, and the inset recess is curved on at least one end of the longitudinal slot.

17. The solar mounting assembly of claim 12 , wherein the longitudinal slot is open on one end.

18. The solar mounting assembly of claim 12 , wherein the support block is aluminum.

19. The solar mounting assembly of claim 12 , wherein the top surface has a recessed surface concentric with the aperture to receive a washer.

Assignees

• Pegasus Solar Inc

Inventors

• Stephan Erich Kai
• Harris Glenn

Classifications

• H02S20/23 Primary

  specially adapted for roof structures · CPC title

• F24S25/61

  for fixing to the ground or to building structures · CPC title

• F24S2025/013

  Stackable support elements · CPC title

• F24S25/40

  using plate-like mounting elements, e.g. profiled or corrugated plates; Plate-like module frames  (extending in directions away from a supporting surface F24S25/10) · CPC title

• Y02B10/20

  Solar thermal · CPC title