# US 7,745,722 B2 · System for mounting a solar module on a roof or the like and method of installing

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- Number: US 7,745,722 B2
- Document ID: US7745722B2
- Status: Granted
- Kind: B2
- Application number: 11/533,990
- Filed: 2006-09-21
- Published: 2007-04-12
- Granted: 2010-06-29
- Earliest claimed: 2005-10-06
- Assignees: BP Corporation North America Inc.
- Inventors: Donald B. Warfield; Paul L. Garvison
- Web page: https://patentgrep.com/patent/US7745722B2

## CPC

- H02S 20/23: specially adapted for roof structures
- F24S 20/67: in the form of roof constructions (in the form of shingles or tiles F24S20/69)
- F24S 25/20: Peripheral frames for modules
- F24S 25/61: for fixing to the ground or to building structures
- F24S 25/70: with means for adjusting the final position or orientation of supporting elements in relation to each other or to a mounting surface; with means for compensating mounting tolerances
- F24S 2025/6006: {by using threaded elements, e.g. stud bolts}
- Y02A 30/60: Planning or developing urban green infrastructure
- Y02B 10/10: Photovoltaic [PV]
- Y02B 10/20: Solar thermal
- Y02E 10/44: Heat exchange systems
- Y02E 10/47: Mountings or tracking
- Y02E 10/50: Photovoltaic [PV] energy
- H02S: GENERATION OF ELECTRIC POWER BY CONVERSION OF INFRARED RADIATION, VISIBLE LIGHT OR ULTRAVIOLET LIGHT, e.g. USING PHOTOVOLTAIC [PV] MODULES (obtaining electrical energy from radioactive sources G21H1/12; light sensitive inorganic semiconductor devices H10F; light sensitive organic semiconductor devices H10K30/00; thermoelectric devices H10N10/00; pyroelectric devices H10N15/00)
- F24S: SOLAR HEAT COLLECTORS; SOLAR HEAT SYSTEMS (for producing mechanical power from solar energy F03G6/00)
- Y02A: TECHNOLOGIES FOR ADAPTATION TO CLIMATE CHANGE
- Y02B: CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO BUILDINGS, e.g. HOUSING, HOUSE APPLIANCES OR RELATED END-USER APPLICATIONS
- Y02E: REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION

## Abstract

A system and method for installing a solar module on a roof using a mounting structure which can be adjusted after it has been fixed to the roof. The mounting structure is comprised of a plate having a slot into which an adjustable bracket is slidably positioned. The mounting structures are spaced from each other and the plates are fixed to the roof by toggle bolts or the like. A framed module is placed across the structures and one or both of the adjustable brackets are adjusted to align holes in the frame of the module with threaded chambers in the brackets. Next, threaded fasteners are passed through the holes and into the chambers to thereby secure the solar module to the roof.

## Claims

### Claim 1

A solar array comprising:
at least two separate mounting structures each separate mounting structure comprising:
a plate adapted to be secured to a support surface, said plate having a top side, a bottom side, and a slot therein; and
a bracket positioned in said slot in said plate and able to slide within the slot, allowing adjustment of the bracket;
at least one solar module, which comprises a frame; and
means for securing said frame of said at least one solar module to said bracket;
wherein a length and a width of said plate are each less than a width of said at least one solar module; and
the said at least two separate mounting structures, when secured to a support surface, are spaced from each other at a distance approximately equal to one side of the at least one solar module whereby said at least one solar module spans said distance between said at least two separate mounting structures.

### Claim 2 (depends on 1)

The solar array of claim 1 wherein said bracket comprises:
a flange; and
an upstanding portion affixed to said flange and extending upward through said slot, said upstanding portion having an internal threaded chamber formed therein.

### Claim 3 (depends on 2)

The solar array of claim 2 wherein said frame of said at least one solar module having sides which encase said at least one solar module; each of two opposing sides of said frame of said at least one solar module having a hole therein which is aligned with said threaded chamber in a respective said bracket when said at least one solar module spans said distance between said at least two separate mounting structures; and
threaded fasteners positioned through said respective hole in said frame and threaded into said respective threaded chamber to thereby secure said at least one solar module to said at least two separate mounting structures.

### Claim 4 (depends on 3)

The solar array of claim 3 including:
sealant substantially surrounding the perimeter of each of said at least two plates.

### Claim 5 (depends on 4)

The solar array of claim 4 further comprising:
a plurality of solar modules; and
a plurality of mounting structures, at least two mounting structures of said plurality of mounting structures are spaced from each other to secure each solar module of said plurality of solar modules to said support surface.

### Claim 6 (depends on 5)

The solar array of claim 5 wherein said support surface is a roof of a building, and adjacent modules of said plurality of solar modules overlap when installed.

### Claim 7

A method of installing an array of solar modules, said method comprising:
providing at least two separate mounting structures, wherein the said at least two separate mounting structures comprise:
a plate adapted to be secured to a support surface, said plate having a top side, a bottom side, and a slot therein; and
a bracket positioned in said slot in said plate and able to slide within the slot, allowing adjustment of the bracket, said bracket having means for receiving a fastener for securing a solar module to said at least two separate mounting structures;
the said plate having a length and width, each of a dimension less than a width of said solar module;
the said solar module having a frame;
securing said at least two separate mounting structures on a support surface and spaced from each other at a distance equal to approximately a length of one side of the said solar module;
positioning the said solar module across said at least two separate mounting structures;
adjusting said bracket in one or both of said at least two separate mounting structures after said at least two separate mounting structures are secured to said support surface, thereby aligning holes in opposing sides of said solar module to said bracket of said at least two separate mounting structures; and
passing fasteners through said holes in said solar module and into said respective mounting means of said brackets to thereby secure said solar module to said support surface.

### Claim 8 (depends on 7)

The method of claim 7 wherein said holes in said solar module are formed in the sides of said frame that encases said solar module.

### Claim 9 (depends on 8)

The method of claim 8 wherein said bracket comprises:
a flange; and
an upstanding portion affixed to said flange and extending upward through said slot;
wherein said means for receiving said fasteners comprises a threaded chamber formed internally within said upstanding portion of said bracket.

### Claim 10 (depends on 9)

The method of claim 9 wherein said plate of said at least two separate mounting structures is secured to said support surface by toggle bolts.

### Claim 11 (depends on 10)

The method of claim 10 including: sealing said plates of said mounting structures to the support surface.

### Claim 12 (depends on 10)

The method of claim 10 wherein said support surface is a roof of a building, and adjacent modules overlap when installed.