Photovoltaic mounting system with chemical flashing

Patent metadata

Field	Value
Publication number	US-9853594-B2
Application number	US-201615051346-A
Country	US
Kind code	B2
Filing date	Feb 23, 2016
Priority date	Feb 25, 2015
Publication date	Dec 26, 2017
Grant date	Dec 26, 2017

Abstract

Photovoltaic mounting systems that form chemical flashings are provided herein. Such sealant injection systems provide directional control and containment of sealant flow to form a chemical flashing that improves sealing of roof penetrations. Such systems can include a base assembly adapted to mount to a roof surface and support a mounting bracket having a photovoltaic module coupling device. The base assembly can include a sealant guide, a compressing plate and a sealant cartridge held between the guide and compressing plate by one or more coupling features of the guide. The coupling features can include a first set of features, such as a series of tabs, that facilitate coupling between the guide and the compressing plate. The base assembly can further include a base that releasably couples to the sealant guide by a second set of coupling features. Methods of mounting such base assemblies on roof surfaces are also provided.

First claim

What is claimed is:

1. A photovoltaic mounting system for mounting on a roof surface, the system comprising:
a base assembly adapted to couple with and support a mounting bracket supporting a photovoltaic module coupling device, wherein the base assembly includes a through-hole for insertion of a mechanical fastener and further comprises:
a sealant cartridge containing a flowable sealant sealed therein,
a compressing plate;
a sealant guide that includes a first set of coupling features that releasably couple with the cartridge or the compressing member plate so as to hold the base assembly together via the first set of coupling features,
wherein the sealant cartridge is held between the sealant guide and the compressing member within the base assembly,
wherein the first set of coupling features comprises a plurality of tabs extending from or near an outer periphery of the sealant guide towards the compressing plate and adapted to releasably engage with an outer periphery of the compressing plate so as to maintain the sealant cartridge between the sealant guide and the compressing plate.

2. The photovoltaic mounting system of claim 1 , wherein the compressing plate includes a one or more openings along the periphery thereof that are arranged so as to receive a distal retention feature of each of the plurality of tabs.

3. The photovoltaic mounting system of claim 1 , wherein the compressing plate has a convex outer surface facing away from the sealant guide so as to inhibit accumulation of rain and/or debris when mounted on the roof surface.

4. The photovoltaic mounting system of claim 1 , wherein each of the plurality of tabs of the first set includes a release feature on a distal end thereof to facilitate manual release of the compressing member by pressing against the release features of the plurality of tabs.

5. The photovoltaic mounting system of claim 1 , wherein the base assembly further comprises:
a base adapted to releasably couple to the sealant guide by a second set of coupling features of the sealant guide.

6. The photovoltaic mounting system of claim 5 , wherein the base has an underside recess on a roof-facing side so as to define a space between the base and the roof when mounted thereon for flowable sealant to fill so as to form the chemical flashing.

7. The photovoltaic mounting system of claim 1 , wherein the cartridge comprises a breakable seal on a roof facing side so as to facilitate directionally controlled release of flowable sealant through the seal upon fastening of the base assembly onto the roof.

8. The photovoltaic mounting system of claim 7 , wherein one or more barbs extend from the sealant guide or an attached base, the one or more barbs being directed towards the breakable seal so as to facilitate breaking of the seal upon fastening of the base assembly to the roof surface.

9. A photovoltaic mounting system for mounting on a roof surface, the system comprising:
a base assembly adapted to couple with and support a mounting bracket supporting a photovoltaic module coupling device, wherein the base assembly includes a through-hole for insertion of a mechanical fastener and further comprises:
a sealant cartridge containing a flowable sealant sealed therein,
a compressing plate;
a sealant guide that includes a first set of coupling features that releasably couple with the cartridge or the compressing member plate so as to hold the base assembly together via the first set of coupling features,
wherein the sealant cartridge is held between the sealant guide and the compressing member within the base assembly,
wherein the sealant guide includes a central hole for passage of the mechanical fastener therethrough and a series of apertures distributed radially about the central hole so as to facilitate uniform distribution of flowable sealant around any roof surface penetration through which the mechanical fastener extends when mounted on the roof surface.

10. The photovoltaic mounting system of claim 9 , wherein the base includes a central hole for passage of the mechanical fastener therethrough and a plurality of openings distributed about the central hole that are aligned with the plurality of apertures in the sealant guide when mounted on the roof surface.

11. The photovoltaic mounting system of claim 10 , wherein the second set of coupling features comprises a plurality of tabs extending towards the base, each of the plurality of tabs having a distal retention feature adapted to engage an edge of the plurality of openings in the base.

12. The photovoltaic mounting system of claim 11 , wherein the retention feature comprises an outwardly extending wedge shaped portion positioned to facilitate lateral deflection of the plurality of tabs upon pressing of the guide against the base and provide a snap-fit coupling between the guide and the base.

13. A photovoltaic mounting system for mounting to a roof surface, the system comprising:
a base assembly adapted to couple with and support a mounting bracket supporting a photovoltaic module coupling device, wherein the base assembly includes a through-hole for insertion of a mechanical fastener and further comprises:
a base,
a compressing member,
a sealant guide having first set of coupling features adapted to releasably couple with the compressing member, and
a sealant cartridge having a sealant reservoir containing a flowable sealant sealed therein,
wherein the sealant cartridge is fittingly received within the sealant guide and held between the sealant guide and the compressing member within the base assembly by the first set of coupling features,
wherein the first set of coupling features include a plurality of protrusions fittingly received within corresponding openings in the compressing member.

14. The photovoltaic mounting system of claim 13 , wherein the plurality of protrusions comprises a plurality of tabs, each of the plurality of tabs of the first set includes a release feature on a distal end thereof to facilitate manual release of the compressing member by pressing against the release features of the plurality of tabs.

15. The photovoltaic mounting system of claim 13 , wherein the sealant guide, sealant reservoir and base are integrated within a single component having ribs or gussets that provide sufficient support to maintain the sealant sealed within the sealant reservoir prior to installation yet allow directionally controlled collapse of the reservoir when the base assembly is fastened to the roof surface during installation.

16. The photovoltaic mounting system of claim 13 , wherein the base assembly further includes:
a reinforcing ring adapted to fittingly receive the sealant cartridge and provide reinforcement against blow-out of sealant through a side-wall of the sealant cartridge.

Assignees

• Solarcity Corp

Inventors

• Almy Charles

Classifications

• F24S25/61

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

• Y02B10/20

  Solar thermal · CPC title

• Y02E10/47

  Mountings or tracking · CPC title

• H02S20/23 Primary

  specially adapted for roof structures · CPC title

• F24S2025/021

  Sealing means between support elements and mounting surface · CPC title