Photovoltaic mounting system with chemical flashing

#This is related to Non-Provisional patent application Ser. No. 14/949,820 filed on Nov. 23, 2015 and Non-Provisional patent application Ser. No. 15/007,154 filed on Jan. 26, 2016; each of which is incorporated herein by reference in its entirety for all purposes.

#This invention relates to mounting system for photovoltaic modules or so-called “solar panels.”

#The present invention relates to photovoltaic mounting systems, and in particular mounting systems adapted to form a chemical flashing about any roof penetrations associated with the mounting system. In various embodiments, the system includes a cartridge of sealant material that provides a chemical flashing when mounted on a roof surface. In various embodiments, the cartridge of sealant material is discharged between the photovoltaic mounting system and roof surface by the torqueing down of a mechanical fastener connecting the mounting system to the roof surface. In various embodiments, the mechanical fastener can be a lag bolt, while in other embodiments, the mechanical fastener can a hanger bolt. In various embodiments, the system can further include a compressing member or plate that presses against a base assembly to compress the sealant cartridge, which forces the sealant through apertures defined in the base assembly to form a chemical flashing on the roof surface. The chemical flashing is formed to provide a water resistant seal around the mechanical fastener. In various embodiments, the compressing plate can be a rigid disk, although in various other embodiments, the compressing plate can be formed in different shapes. In various embodiments, the system can include a photovoltaic module mounting bracket having a photovoltaic module coupling device that is attached to the base assembly. In some embodiments, the module mounting bracket is attached to the base assembly via a nut and the top threaded portion of the hanger bolt attaches the base assembly to the roof surface. The base assembly can be formed in a circular shape resembling a puck, although it is appreciated that the base assembly can be formed in various non-circular shapes (e.g. oval, square, rectangular) as needed for a particular application. In one aspect, the invention relates to a photovoltaic mounting system for mounting on a roof surface that includes a base assembly adapted to couple with and support a mounting bracket supporting a photovoltaic module coupling device. The base assembly includes a through-hole for insertion of a mechanical fastener. In various embodiments, the base assembly includes a sealant guide, a compressing member or plate, and a sealant cartridge containing a flowable sealant sealed. In various embodiments, the sealant cartridge is held between the sealant guide and the compressing member within the base assembly without requiring any additional separate coupling members to maintain the assembly. One or more of the sealant guide, the base and the compressing plate can include one or more coupling features for releasably securing the components of the base assembly together without requiring any additional separate coupling member, such as a mechanical fastener or other fastening member.

#FIGS. 1 and 2 illustrate an assembled view and an exploded view of a photovoltaic mounting system adapted to form a chemical flashing according to an exemplary embodiment.

#FIGS. 3A-3C illustrate several views of a base assembly of a photovoltaic mounting system according to an exemplary embodiment.

#FIG. 4 illustrates an exploded view of a base assembly of a photovoltaic mounting system according to an exemplary embodiment.

#The following description is intended to convey a thorough understanding of the embodiments described by providing a number of specific embodiments and details involving PV mounting hardware for shingled roofs. It should be appreciated, however, that the present invention is not limited to these specific embodiments and details, which are exemplary only. It is further understood that one possessing ordinary skill in the art, in light of known systems and methods, would appreciate the use of the invention for its intended purposes and benefits in any number of alternative embodiments, depending upon specific design and other needs.

#Referring now to FIGS. 1-8, these Figures show various views of a photovoltaic mounting system according to various embodiments of the invention. As shown in FIG. 1, mounting system 100 includes a base portion 110, mounting bracket 120 and photovoltaic module coupling device 130. As can be seen in the exploded view of FIG. 2, a fastener, such as hanger bolt 121, is used to fasten mounting bracket 120 to base portion 110 and to mount base portion 110 to the roof surface. Bolt head 121a engages a top surface of base portion 110 to mount onto the roof surface and mounting bracket 120 is secured to base portion 110 by nut 112 threaded onto the upper threaded region of hanger bolt 121.

#As shown in FIG. 3A-3C, base portion 110 includes sealant cartridge 115 that sits between compressing plate 116 and base 112. Compressing plate 116 may take the form of a bell housing or simply be a plate or can be formed in any suitable shape for pressing against cartridge 115 so as to release the flowable sealant thereby forming the chemical flashing. Base 112 can be formed in a circular, puck shape, although it is appreciated that base 112 can also be formed in various other non-circular shapes as well. In some embodiments, base 112 is formed of a durable, rigid, corrosion resistant material, for example a metal alloy, such as steel, aluminum or hard plastic. Sealant cartridge 115 contains a flowable sealant that is released upon mounting of base assembly 110 to form the chemical flashing. In various embodiments, base 112 includes a recess on its bottom, roof-facing side, that circumscribes its perimeter and that is dimensioned to receive the top of sealant ring 111 to keep sealant material captured under base portion 110 when the assembly is attached to a roof or other support surface. Sealant ring 111 can be attached to base 112 by any suitable means, for example a pressure-sensitive adhesive. As shown in FIGS. 3A-4, base portion 110 can be defined as a stacked assembly, although it is appreciated that in various other embodiments some or all of the components of the assembly can be integrated.