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.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
       [0001]    This claims the benefit of priority of U.S. Provisional Patent Application No. 62/260,178 [Atty Docket No. P124-3PUS] filed on Nov. 25, 2015 and U.S. Provisional Patent Application No. 62/120,841 [Atty Docket No. P124-1PUS] filed on Feb. 25, 2015; each of which is incorporated herein by reference in its entirety. 
     
    
       [0002]    This is related to Non-Provisional Patent Application No. 14/949,820 [Atty Docket No. P124-2NUS] filed on Nov. 23, 2015 and Non-Provisional Patent Application No. 15/007,154 [Atty Docket No. P235-1NUS] filed on Jan. 26, 2016; each of which is incorporated herein by reference in its entirety for all purposes. 
       FIELD OF THE INVENTION 
       [0003]    This invention relates to mounting system for photovoltaic modules or so-called “solar panels.” 
       SUMMARY OF THE INVENTION 
       [0004]    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. 
         [0005]    In various embodiments, the base assembly includes a sealant guide having a first set of coupling features that releasably couple with the sealant cartridge or the compressing plate to hold the base assembly together via the one or more coupling features. The first of coupling features can include multiple tabs extending from or near an outer periphery of the sealant guide towards the compressing plate that are adapted to releasably engage with an outer periphery of the compressing plate to maintain the sealant cartridge between the sealant guide and the compressing plate. The compressing plate can include one or more openings along the periphery thereof that are arranged to receive a distal retention feature on each of the plurality of tabs. In various embodiments, 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. 
         [0006]    In various embodiments, the base assembly includes a base adapted to releasably couple to the sealant guide by a second set of coupling features of the sealant guide. The sealant guide includes a central hole for passage of the mechanical fastener and a series of apertures distributed radially about the central hole to facilitate uniform distribution of flowable sealant around any roof surface penetration through which the mechanical fastener extends when mounted on the roof surface. The base also includes a central hole for passage of the mechanical fastener and multiple openings distributed about the central hole that are aligned with the plurality of apertures in the sealant guide when mounted on the roof surface to allow flow of sealant therethrough. In various embodiments, the second set of coupling features comprises a plurality of tabs extending towards the base, each of the tabs having a distal retention feature adapted to engage an edge of the multiple openings in the base. In various embodiments, the retention feature is defined as an outwardly extending wedge shaped portion positioned to facilitate lateral deflection of the tabs when the guide is pressed against the base so as to provide a snap-fit coupling between the guide and the base. In various embodiments, the base has an underside recess on a roof-facing side that defines a space between the base and the roof when mounted thereon for flowable sealant to fill so as to form the chemical flashing. In addition, a sealant ring can be used to define and seal a space between the base and roof surface in which the chemical flashing is formed. 
         [0007]    In another aspect, the photovoltaic mounting system includes a base assembly having a sealant cartridge with a breakable seal on a roof facing side to facilitate directionally controlled release of flowable sealant through the seal upon fastening of the base assembly onto the roof. The base assembly can further include a sealant guide for supporting that sealant cartridge and securing the sealant cartridge to a base or the guide can be integrated with the base. The sealant guide can include one or more puncture tubes with one or barbs directed towards the breakable seal to facilitate breaking of the seal upon fastening of the base assembly to the roof surface. 
         [0008]    In various embodiments, the base assembly includes a compressing member disposed atop a collapsible sealant cartridge. The compressing plate can be defined as a compressing plate having a planar surface for engaging and pressing against the sealant cartridge. The top of the compressing plate facing away from the sealant cartridge can be defined as a convex outer surface face to inhibit accumulation of rain and/or debris when mounted on the roof surface. Typically, the compressing plate is defined has a circular shape, although it is appreciated that the compressing plate can be formed in various other non-circular shape. In various other embodiments, the compressing plate is defined as a bell-type shape having an outer periphery that extends further below an interior portion that engages against the top of the sealant cartridge. This bell-type shape allows the outer periphery of the compressing plate to seal against the roof and/or a sealant ring on the roof so as to enclose the compressed sealant reservoir therein and contain any excess sealant extruded when the assembly is mounted onto the roof surface. 
         [0009]    In various embodiments, a photovoltaic mounting system for mounting to a roof surface 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, such as a lag bolt or a hangar bolt. In various embodiments, the base assembly includes a base, a compressing member, a sealant guide having a first set of coupling features adapted to releasably couple with the compressing member and a sealant reservoir containing a flowable sealant sealed. The sealant cartridge is held between the sealant guide and the compressing member by the first set of coupling features. The first set of coupling features include a plurality of protrusions fittingly received within corresponding openings in the compressing member. In various embodiments, each of the tabs of the first set includes a release feature on a distal end to facilitate manual release of the compressing member by pressing against the release features of the plurality of tabs. 
         [0010]    In various embodiments, the photovoltaic mounting system includes a base assembly having an integrated sealant guide and base. In some embodiments, the integrated sealant guide base can further include an integrated sealant reservoir. In other embodiments, the sealant guide base can be used with a removable sealant cartridge. In various embodiments, the sealant guide, sealant reservoir and base are integrated within a single component having ribs or gussets that provide sufficient support to maintain sealed sealant reservoir yet allow directionally controlled collapse of the reservoir when the base assembly is fastened to the roof surface. 
         [0011]    In various embodiments, the photovoltaic mounting system includes a base assembly with a sealant cartridge and a reinforcement ring disposed about the cartridge. The reinforcing ring is adapted to provide reinforcement against blow-out of sealant through a side-wall of the sealant cartridge. In various embodiments, the reinforcing ring is adapted to fittingly receive the sealant cartridge and extends above the roof surface a lower height than the cartridge so as to allow compression of the sealant cartridge during installation. 
         [0012]    In various embodiments, the photovoltaic mounting system includes a photovoltaic module coupling device, a mounting bracket supporting the photovoltaic module coupling device, and a base assembly releasably coupled to the mounting bracket and having a through-hole for insertion of a mechanical fastener. The base assembly can include a sealant guide, a compressing member, 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. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0013]      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. 
           [0014]      FIGS. 3A-3C  illustrate several views of a base assembly of a photovoltaic mounting system according to an exemplary embodiment. 
           [0015]      FIG. 4  illustrates an exploded view of a base assembly of a photovoltaic mounting system according to an exemplary embodiment. 
           [0016]      FIGS. 5A and 5B  illustrate an exploded view and an exploded view, respectively, of a base assembly of a photovoltaic mounting system according to an exemplary embodiment. 
           [0017]      FIGS. 6A-6C  illustrate sequential views showing installation of a base assembly of a photovoltaic mounting system according to an exemplary embodiment. 
           [0018]      FIGS. 7A and 7B  illustrate an exploded view and an assembled view, respectively, of a photovoltaic mounting system adapted to form a chemical flashing according to an exemplary embodiment. 
           [0019]      FIGS. 8 and 9  illustrate an assembled view and an exploded view, respectively, of a photovoltaic mounting system adapted to form a chemical flashing according to another exemplary embodiment. 
           [0020]      FIG. 10  illustrates an exploded view of a base assembly of the photovoltaic mounting system of  FIG. 9 . 
           [0021]      FIG. 11  illustrates select components of the base assembly of the photovoltaic mounting system of  FIG. 9 . 
           [0022]      FIG. 12A  illustrates an exploded view of a base assembly of a photovoltaic mounting system according to another exemplary embodiment. 
           [0023]      FIG. 12B  illustrates an exploded view of a base assembly of a photovoltaic mounting system according to yet another exemplary embodiment. 
           [0024]      FIG. 13  illustrates several views of a base of the base assembly shown in  FIG. 12B . 
           [0025]      FIGS. 14A and 14B  illustrate bases for use in a base assembly of a photovoltaic mounting system according to alternative embodiments. 
           [0026]      FIG. 15  illustrates a photovoltaic mounting system according to another exemplary embodiment. 
           [0027]      FIG. 16  illustrates an exploded view of the photovoltaic mounting system shown in  FIG. 15 . 
           [0028]      FIG. 17A  illustrates an exploded view of the base assembly of the photovoltaic mounting system shown in  FIG. 15 . 
           [0029]      FIG. 17B  illustrates a detailed view of the pins of the sealant reservoir heat bonded to corresponding holes in compressing plate of the base assembly in  FIG. 17A . 
           [0030]      FIG. 18  illustrates an exploded view of the base assembly components according to another embodiment of a photovoltaic mounting system. 
           [0031]      FIGS. 19A-19C  illustrate sequential cross-sectional views of an exemplary photovoltaic mounting system before, during and after installation according to various embodiments. 
           [0032]      FIG. 20  illustrates an underside view of an integrated guide base according to another embodiment of a photovoltaic mounting system. 
           [0033]      FIGS. 21A and 21B  illustrate a cross-sectional detailed and an underside view, respectively, of the integrated guide base in  FIG. 20  indicating a sealant flow path during installation according to various embodiments. 
           [0034]      FIG. 22  illustrates a photovoltaic mounting system according to another exemplary embodiment. 
           [0035]      FIG. 23  illustrates an exploded view of the photovoltaic mounting system of  FIG. 22 . 
           [0036]      FIG. 24A  illustrates an exploded view of the base assembly of the photovoltaic mounting system of  FIG. 22 . 
           [0037]      FIG. 24B  illustrates an assembled view of the base assembly of the photovoltaic mounting system of  FIG. 22 . 
           [0038]      FIGS. 25A and 25B  illustrate perspective views of the top-side and the bottom, roof-facing side, respectively, of an integrated guide base of the photovoltaic mounting system of  FIG. 22 . 
           [0039]      FIG. 26  illustrates a cross-sectional side of the integrated guide base of the photovoltaic mounting system of  FIG. 22 . 
       
    
    
     DETAILED DESCRIPTION 
       [0040]    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. 
         [0041]    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  121   a  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 . 
         [0042]    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. 
         [0043]    As shown in  FIGS. 3A-3C and 4 , base  112  can include center hole  113  for passage of a mechanical fastener and apertures  113 A to allow extrusion of the flowable sealant therethrough. Apertures  113 A may be distributed around center hole  113  to allow for even distribution of sealant material under base  112 . In this embodiment, apertures  113 A are distributed radially about center hole  113  to provide more uniform distribution of sealant about the roof penetration that the fastener extends through. While three apertures are shown here, each defined in a trapezoidal-shape, it is appreciated that the apertures could be formed in various differing shapes and numbers. For example, apertures  113 A can be formed also as circular holes or could be formed as a single opening extending partly or entirely about center hole  113 . 
         [0044]    As can be seen in  FIG. 4 , cartridge  115  comprises a cylindrical-shaped structure with a center through-hole  115 A. Cartridge  115  can be formed of any suitable material, for example plastic, that can contain a flowable sealant in a sealed state. In various embodiments, the housing of cartridge  115  can be formed, partly or entirely, of a material that can be crushed or collapsed so as to allow release of the flowable sealant upon mounting of base portion  110  to the roof. In various embodiments, one side of cartridge  115  facing towards base  112  may be covered with foil or other material that is strong enough to provide an airtight seal to prevent the sealant form curing but breakable enough to easily penetrated or ruptured during installation to release the sealant. A plastic bracket such as sealant carrier or guide  114  may surround cartridge  115 , keep center-hole  115 A of cartridge  115  over center opening  113  in base  112 , and also function as mechanical fastener to connect cartridge  115  and compressing plate  116  to base  112  to form a single assembly. 
         [0045]    In various embodiments, sealant guide  114  includes one or more coupling features that act as mechanical fasteners to couple guide  114  to one or both of compressing plate  116  and base  112  with sealant cartridge  115  secured therebetween. In these embodiments, the one or more coupling features are defined as one or more tabs, typically a series of tabs distributed about the periphery of guide  114 . As can be in seen in  FIG. 4 , guide  114  include multiple tabs  114 B that extend upwards toward compressing plate  116 . Each tab can include a retention feature  14 C on a distal end thereof. Retention feature  14 C can be defined as an inwardly bent or curved end adapted to engage a top, outer surface of compressing plate  116  sufficiently to couple guide  114  with compressing plate  116 . In some embodiments, tabs  114 B are adapted to receive and fit over an outer periphery of compressing plate  116  and engage an outer surface, such as shown in  FIG. 3A . Tabs  114 B are formed of a material with sufficient rigidity and strength to resiliently deflect to receive compressing plate  116  and apply enough tension to securely couple compressing plate  116  to guide  114  with sealant cartridge  115  held in between. In some embodiments, tabs  114 B are adapted to interface with corresponding retention features  116 B within compressing plate  116 . In this embodiment, the corresponding retention features  116 B are defined as square openings dimensioned to receive the distal retention feature of tabs  114 B. It is appreciated that the assembly can be designed so that tabs  114 B interface with the corresponding retention features  116 B from outside the periphery, as shown in  FIG. 3A , or from inside the periphery, as shown in  FIG. 3B . Distal retention features  114 C can be defined as wedge-shaped portions that are positioned so that an angled portion deflects tabs  114 B when compressing plate  116  is pressed onto guide  114  until the wedge-shaped portion is received into the square openings, such as in a snap-fit type coupling. In such embodiments, the wedge-shaped portion can be dimensioned to extend beyond the square openings when guide  114  is snap-fit coupled to compressing plate  116  to allow a user to disassemble base portion assembly  110  by pressing on the portions of tabs  114 B protruding from compressing plate  116 . 
         [0046]    In various embodiments, guide  114  can further include coupling features for securing base  112  to guide  114 . As shown in  FIG. 4 , such coupling features can be defined as multiple tabs  114 A distributed along the periphery of guide and extending towards base  112 . Similar to the mechanism described above with respect to tabs  114 B, tabs  114 A are shaped so as to be resiliently received within corresponding retention features within base  112 . In this embodiment, the corresponding retention features are also apertures  113 A through which sealant is extruded. As can be seen in  FIG. 4 , tabs  114 A are positioned to be received along an outside edge of each of apertures  113 A and include distal retention feature  114 D defined as a wedge-shaped portion that facilitates lateral deflection of tabs  114 A until distal retention feature  14 D is received along the lower edge of apertures  113 . While in this embodiment, the corresponding features of base  112  are integrated with apertures  113 A, it is appreciated that base  112  could include separate retention features, for example a series of openings similar to those in compressing plate  116 . 
         [0047]    In any of the embodiments herein, it is appreciated that one or more retention features, such as tabs  114 A and  114 B, can be used to secure the elements of base portion  110  within an assembly. Such retention features can be adapted to permanently secure the components together or to releasably secure the components together so as to allow an end-used to disassemble base portion if needed. While retention features  116 B are shown as square or rectangular openings and tabs  114 A and  114 B are shown as having rectangular cross-sections, it is appreciated that various other shapes could be used in keeping with retention mechanisms described above. 
         [0048]    As shown for example in  FIG. 5 , guide base  114  may include a set of openings  114 E which overlap or match up with apertures  113 A of base  112  so that flowable sealant flows through both openings  114 E and base  113 A when cartridge  115  is compressed. Guide  114  can further include a set of tabs  114 A on the base-facing side that detachably couple guide base  114  to base  112 . Also, as seen in  FIG. 5 , base assembly can further include reinforcing ring  118 , which is a rigid ring adapted to fit around cartridge  115  when fitted within guide base  114 . Reinforcing ring  118  is made of a suitable material and dimension to provide resistance to the lateral flow of sealant through the sidewall of cartridge  115  when cartridge  115  is compressed against base  112  otherwise known as a “blow-out.” As seen here, reinforcing ring extends only partly along the side to allow cartridge to be compressed to about the height dimension of the reinforcing ring. 
         [0049]    In such embodiments, guide base  114  may also include a set of upward-facing tabs  114 B, that face away from base  112 , that engage a compressing member such as compressing plate  116 . In various embodiments, compressing plate  116  is a disc-shaped structure with a lip surrounding the outer edge that curves downward toward base  112 . Compressing plate  116  may be made of a rigid material such as galvanized steel, stainless steel, aluminum, etc., that is strong enough to compress cartridge  115  without distorting. In various embodiments, compressing plate can be formed in a shape having a convex top surface on a side facing away from the roof surface, which inhibits accumulation of rain and/or debris when mounted on the roof surface. 
         [0050]    Compressing plate  116  may include one or more retention features (e.g. recesses, openings) positioned to match with location of tabs  114 B formed on guide base  114  so that compressing plate  116  will remain mechanically coupled to the entire assembly, for ease of transport and installation. Housing of compressing plate  116  includes central opening  116 A which is co-located with opening  115 A in cartridge  115  and opening  112 A in base  112 . 
         [0051]      FIGS. 6A-6C  illustrate the process of mounting an exemplary base portion assembly  110  to a roof surface using a hanger bolt  121  as the mechanical fastener. Base assembly  110  is installed by first drilling a pilot hole into a roof surface, for example, directly through any existing shingles. After the pilot hole has been drilled, base assembly  110  may be positioned over the pilot hole, as shown in  FIG. 6A  and hanger bolt  121  inserted through aperture  116 A in compressing plate  116 , aperture  115 A in cartridge  115 , through guide base  114  and through aperture  112 A in base  112 , and into the pilot hole. Then, using an impact driver or other tool, torque is applied to hanger bolt  121  until head  121 A engages the top surface of compressing plate  116 , which in turn begins to crush cartridge  115 . As torque is continuously applied, compressing plate  116  continued to crush cartridge  115  until the bottom of the lip of the outer periphery of compressing plate  116  rests against the top surface of base  112 . Tabs  114 A (not shown) can be deflected outward or break off as the compressing plate  116  moves downward. 
         [0052]    During this torqueing process, sealant will be forced through the openings in the bottom of guide base  114 , through apertures  113  in base  112  and underneath to seal around lag bolt  121  and any missed drill holes that are also within the void defined by base  112  and sealant ring  111 . 
         [0053]      FIGS. 7A and 7B  show an exploded view and an assembled view of a photovoltaic mounting bracket  120  and base assembly  110 . In various embodiments, bracket  120  includes an opening, such as slot  124 , through which the top of lag bolt  121  passes when assembled. Nut  122  rests against top surface  123  of bracket  120  so as to hold bracket  120  against base assembly  110 . Slot  124  allows mounting bracket  120  to be rotated  360  degrees about lag bolt  121  as well as moved laterally along the primary axis of bracket  120 . Such a configuration allows for adjustment of mounting bracket as needed for a position of a photovoltaic module mounted on the roof surface. 
         [0054]    Bracket  120  can further include raised portion  125  that supports photovoltaic coupling device  130 . An advantage of this design is that raised portion  125  provides extra clearance for mounting hardware supporting PV coupling device  130 , such as, for example, nut  122 . In various embodiments, PV coupling device  130  is supported above raised portion  125  by a threaded stud such as stud  131 . An advantage of this is, is that adjustments can be made to the height of PV module coupling device  130  and base assembly  110  (and by extension between device  130  and the roof surface) to compensate for an uneven roof surface. 
         [0055]    As shown in the figures, PV module coupling device  130  can include a rock-it connector such as connector  133  manufactured by SolarCity Corp. Such a coupling device is described and illustrated, for example, in commonly assigned U.S. patent application Ser. No. 14/615,320, Publication No. 2015/0155823-A1, the disclosure of which is herein incorporated by reference in its entirety. However, it should be appreciated that a clamping or wrap-around style connector, or other types of connectors, may be utilized with various embodiments with departing from the spirit or scope of the invention. 
         [0056]    Referring now to  FIGS. 8-14 , these figures show a photovoltaic module mounting system adapted to form a chemical flashing according to another embodiment of the invention. System  200  employs a somewhat different photovoltaic mounting bracket, as shown in  FIGS. 1-7 , that still forms a chemical flashing that is released by the action of a hanger or lag bolt being torqued down to the roof to securely attach the base portion, in this case assembly  210 , to the roof surface. 
         [0057]    As shown in  FIG. 8 , system  200  includes base assembly  210 , mounting bracket  220  and PV module coupling device  130 . Coupling device  130  is substantially the same as the coupling device shown in  FIGS. 1-7 . As in the case of that embodiment, system  200  may include a clamping or wrap-around coupling device in place of rock-it connector  130 . Such variations are with in the spirit and scope of the invention. 
         [0058]    As can be understood by referring to the partly exploded view in  FIG. 9 , hanger bolt  221  is inserted through base assembly  210  to secure it to the roof surface. Then, mounting bracket or foot assembly  220  is placed on top of base assembly  210  via slot  220 A. The top portion of hanger bolt  221  may pass through slot  220 A and then receives nut  222 , which is torqued down to fasten foot assembly  220  to base assembly  210 . Slot  220 A allows the location of PV module coupling device  130  to be moved with respect to hanger bolt  221 , both laterally and rotationally. After mounting is complete, the system appears as shown in  FIG. 8 . 
         [0059]      FIG. 10  is a partially exploded view showing the individual components of base assembly  210 , which include, assembled from bottom to top, sealant ring  211 , base  212 , sealant guide  214 , sealant cartridge  215  and compressing plate  216 . Each of these components of base assembly  210  and their relative position is described in further detail below. 
         [0060]    Base  212  sits on top of sealant ring  211 . Base  212  is preferably made of a rigid, corrosion resistant material, for example a metal alloy, such as steel, aluminum or hard plastic. Base  212  can further include a recess on its underside (e.g., roof-facing side) that is dimensioned to receive sealant ring  211 , which helps prevent leakage of sealant out from the seam between ring  211  and base  212 . Sealant ring  211  can be made of foam or other deformable material so as to define a perimeter under base assembly  210  that contains the flowable sealant as it is extruded through any apertures  212 A in base  212 . Sealant ring  211  can also define a cavity between the bottom of base  212  and the roof surface, which defines the space in which the chemical flashing is formed. Sealant ring can be releasably or fixedly attached to the underside of base  212  by any suitable means, for example a pressure-sensitive adhesive. 
         [0061]    As shown, base  212  further includes one or more holes  212 A for receiving a mechanical faster such as a lag bolt or hanger bolt. As shown, hole  212 A is in the center, however, it should be appreciated that if more than one fastener is used, there may be multiple holes distributed around base  212 . Base  212  further includes one or more apertures  213  for guiding flow of sealant material into the void defined by sealant ring  211 , base  212  and the roof, and around the lag bolt or hanger bolt penetrating into the roof, thereby forming the chemical flashing around the roof penetration. 
         [0062]    Next, in this assembly  210  is sealant cartridge  215  and sealant carrier or guide  214 . Sealant guide  214  sits on base  212  and may include one or more coupling features, such as downward-facing tabs  214 A with distal retention features  214 D, which detachably couple guide  214  to base  212  by a mechanism the same or similar to that described in the embodiment of  FIGS. 1-7 . Guide  214  can further include one or more coupling features, such as upward-facing tabs  214 B that serve to maintain the position of sealant cartridge  215  and also to connect it to compressing plate  216  by distal retention features  214 B. Compressing plate  216  can include a set of corresponding retention features, such as openings  216 A, that receive tabs retention features  214 C of tabs  214 B to keep assembly  210  together before installation. Such coupling features allows the base portion assembly  210  to remain as an assembly without any need for any additional fasteners, such as hangar bolt, extending therethrough. Though not shown in  FIG. 10 , sealant cartridge  215  and guide base  214  may also include a reinforcing ring, such as described previously. Such a reinforcing ring helps keep cartridge  215  seated on guide base  214  and to prevent against blow-outs when compressing plate  216  is compressed down towards base  212 , thereby causing sealant to be dispensed through apertures  213  and under base  212  around bolt  221  and forming the chemical flashing. 
         [0063]      FIG. 11  shows another exemplary reinforcing ring  217 . Reinforcing ring  17  is preferably though not necessarily short enough to allow compressing plate  216  to compress against base  212  without interfering but tall enough to substantially prevent blow outs. Ring  217  can further include orientating and/or coupling features, such as recesses  217 A, which fit into corresponding protrusions  214 E on guide  214 . These features can be adapted to fit together in a snap-fit type coupling so as to secure retaining ring  217 A with guide  214 . Guide  214  further includes openings  214 E that align with corresponding apertures  213  in base  212  through which sealant flows from sealant cartridge  215 . 
         [0064]    Turning now to  FIGS. 12A and 12B , these figures show alternative embodiments of base assembly  210  in which guide  224  and base  223  are slightly different from guide  214  and base  212 . Guide  224  includes a plurality of upward-facing tabs  224 A with distal retention features  224 A which engage corresponding retention features  226 A in compressing plate  226 . In this embodiment, compressing plate  226  has a larger diameter than compressing plate  216 , and can be made larger than sealant ring  211  so that when compressing plate  226  is compressed against cartridge  225  and guide base  224 , the outer periphery of compressing plate  226  extends further down such that it contacts ring  211  as well as the roof surface. In this embodiment, base  223  can be made out of plastic or other less durable material since most or all of base  223  may not be in the load path of the assembly  210 , unlike base  212  previously described. 
         [0065]    As shown in  FIG. 12B , base  223  includes a central hole  223 A for passage of the mechanical fastener and apertures  223 B for passage of flowable sealant. Base  223  can further include one or more puncture tabs  223 T within openings  223 B for facilitating puncture of a bottom portion of sealant cartridge  225 . Puncture tabs  223 T are shown in more detail in  FIGS. 13 . As shown, puncture tabs  22 T include an inwardly projecting tab extending inwardly to an upward projecting barb that is elevated above base  223  when base  223  is set on the roof or other flat surface. Puncture tabs  223 T assist in the rupturing of the seal of cartridge  225  when compressing plate  226  is lagged down towards base  223 . Puncture tabs  223 T can be located at the point of apertures  223 B to further guide the flow of the sealant in cartridge  225  under base  223 . 
         [0066]      FIG. 14  illustrates two variations of the underside of base  223 - 223 B, and  223 B′—which may assist in directing and evenly distributing the flow of sealant material from cartridge  225  under base  223 . Design  223 B is a spiral design in which sealant material is guided outward spirally in an increasing large diameter path starting from the center. Design  223 B′ is a labyrinth design consisting of a series of partial rings in which sealant is simultaneously guided away from the center in three directions, converging around each ring before moving on to the next ring. These or other bottom designs may be utilized with the various embodiments of the invention. It is appreciated that base could include further variations that include channels or geometries that facilitate controlled flow of sealant through the base so as to form a consistent and uniform chemical flashing. 
         [0067]    Referring back to  FIGS. 8 and 9 , mounting bracket assembly  220  may include a section of extrusion or roll formed steel that is somewhat longer than the diameter of base assembly  210 . Bracket assembly  220  may have a downward U cross-sectional shape where the bottom of each side of the U rests on a ridge or flat surface formed in the top of compressing plate  216 . It should be appreciated that this design is merely exemplary and other types of mounting brackets may be used with system  200  shown in these figures. 
         [0068]    Referring now to  FIGS. 15-21 , these figures show a photovoltaic mounting system including a chemical flashing according to various embodiments of the invention. System  300  is similar to that shown in the previous embodiments in that it includes base assembly  310 , mounting bracket  220  and photovoltaic module coupling device  130 . 
         [0069]    One difference over previous embodiments, is that several of the components of base assembly  310  are combined or integrated into a single part. As can be seen in  FIG. 15  and the exploded view in  FIG. 16 , however, the mounting system include an integrated base assembly  310  that is integrated into a single component. Typically, base assembly  310  is integrated such that it cannot be readily disassembled by an end-user. 
         [0070]    A partly exploded view of integrated guide base  311  is shown in  FIG. 17A . As can be seen, in addition to sealant ring  313 , base assembly  311  includes an integrated guide  311  and sealant reservoir  315 . In this embodiment, guide base  311  includes one or more gussets  312  to provide sufficient strength to maintain the integrity of the assembly prior to installation, yet allow directionally controlled collapse upon installation. 
         [0071]    As shown, reservoir  315  includes a center hole  316  for allowing a lag bolt, hanger bolt, or other fastener to pass through. It is appreciated however, that reservoir could be formed in a shape that would not require a central hole or could be formed of a material that would allow the mechanical fastener to puncture the reservoir when inserted therethrough. In some embodiments, reservoir  315  of guide base  311  may include seal of foil or other material on its underside to protect the sealant from the air while still allowing for easy penetration during installation. 
         [0072]    Reservoir  315  can be attached to compressing plate  320  by any suitable means. In the depicted embodiment, reservoir  315  include one more pins  317  for attaching and orienting guide  311  to compressing plate  320 . As shown in  FIG. 17 , compressing plate  320  may be attached to base assembly  310  by pins  317  on the top surface of reservoir  315  which pass through reciprocal holes  320 B formed in compressing plate  320 , which also includes a central hole  320 A for passage of the mechanical fastener. Reservoir can then be secured through a process such as heat staking or ultrasonic bonding, thereby affixing pins  317  and compressing plate  320  to one another, as depicted in the detail cross-section shown at bottom of  FIG. 17 . 
         [0073]    In various embodiments, the underside of reservoir  315  includes a void in which sealant is placed prior to sealing with foil seal  314  underneath that is surrounded by sealant ring  313 , as can be understood by referring to  FIG. 18 . Also, guide base  311  can include multiple gussets  312  to assist in uniform deformation of ring  313  during installation. Typically, gussets  312  are defined as tapered reinforcing ribs that are distributed along an outer wall of the integrated guide base  311 . In various embodiments, the top of reservoir  315  may project higher than the walls of guide base  311  so that reservoir  315  is at least partially compressed by compressing plate  320  before compressing plate  320  engages the top of the remainder of guide base  311 . Installation of system  300  is similar to that shown in other embodiments. A hanger bolt, lag bolt or other fastener is driven into the roof through base assembly  310 . Compressing plate  320  first engages the top of reservoir  315  of guide base  311  and then the top edge of base  311 . Continued torqueing of fastener  221  eventually causes compressing plate  320  to compress reservoir  315  and guide base  311  until reservoir  315  is fully compressed. 
         [0074]    An example of such a configuration is shown in  FIG. 19A-C , which illustrates sequential cross-sectional views before, during and after mounting into the roof surface, respectively. In  FIG. 19A , the top of reservoir  315  can be seen extending above the walls of guide  315 . In  FIG. 19B , compressing plate  320  has partly compressed reservoir  215  and abutted against the top of the walls of guide  215 . In  FIG. 19C , compressing plate  320  has been torqued into the roof surface to entirely compress reservoir  315  and abut against sealant ring  313  and roof surface, thereby extruding the flowable sealant into the space between the base and roof surface to form a chemical flashing along where the bolt  221  penetrates the roof surface. 
         [0075]    As shown in  FIGS. 20 and 21A-21B , guide base  311  can further include one or more vents  318  that allow sealant to flow back up under housing  320  rather than being forced out of the sides around ring  313 . These vents  318  helps prevent any excess sealant from flowing onto the roof surface. The guide base  311  can further include the labyrinth of open channels that facilitate controlled flow of sealant between guide base  311  and the roof surface. 
         [0076]      FIG. 20  shows a detailed view of the underside of guide base  311 . In various embodiments, this may include a chamber or void centered on a lag or hanger bolt opening. In addition, there may be a labyrinth  311 A or other pattern or network of open channels to further guide the flow of sealant under guide base  311 , eventually reaching vent holes  318  which can direct excess sealant back under compressing plate  320  to help prevent blow-outs through the side of ring  313 .  FIG. 21A  shows a detailed cross-sectional view of the sealant flow path (indicated by arrows) as the sealant flow through the labyrinth of channels and excess sealant flows through vent opening  318  into a space between guide base  311  and bell-shaped compressing plate  320 .  FIG. 21B  shows an underside detailed view indicating a sealant flow path through the labyrinth of channels  311 A towards vent openings  318  towards the outer periphery of guide base  311 . 
         [0077]    Referring now to  FIGS. 22-26 , these figures illustrate a photovoltaic mounting system adapted to form a chemical flashing according to yet another embodiment of the invention. As shown in the assembled view of  FIG. 22  and can be understood further in the exploded view of  FIG. 23 , system  400  includes base assembly  410 , mounting bracket  220 , and photovoltaic module coupling device  130 . Elements  220  and  130  are substantially the same or similar to those shown in previous embodiments, such that any previous detailed description can apply also to this embodiment. Base assembly  410  includes compressing plate  420 , sealing ring  411 , sealant cartridge  415  and an integrated guide base  414  that acts as both as a guide for supporting the sealant cartridge as well as a base for placing against the roof surface. An exploded view of base assembly  410  can be seen in  FIG. 24A  and an assembled view is shown in  FIG. 24B . 
         [0078]      FIGS. 25A-25B and 26  show integrated guide base  414  in greater detail,  FIG. 25A  illustrating a top side perspective view,  FIG. 25B  illustrated a bottom roof-facing side perspective view and  FIG. 26  illustrating a cross-sectional side view. Guide base  414  includes substantially planar front surface  414 F and bottom, roof-facing surface  414 B. As shown, roof-facing surface  414 B includes multiple columns or legs  414 L that support assembly  414  and maintain a space during installation in which sealant can flow freely around the hanger bolt and under guide base  414 . Guide base  414  also includes an a central opening  414 A for passage of the fastener, such as a hanger bolt or lag bolt, while allowing contact with the sealant material. A continuous aperture  414 C surrounds the central opening  414 A to allow flowable sealant to flow continuously about the fastener so that the chemical flashing forms is sealed around the mechanical fastener. One or more puncturing tabs  414 T can be included to quickly and evenly rupture any seal on the bottom side of sealant cartridge  415  when sealant cartridge  415  is compressed against guide  414  during installation. As can be seen in  FIG. 26 , the bottom of puncture tabs  414 T extend below the bottom of the spacer columns  414 L such that when guide base  414  is pressed against the roof surface, puncture tabs  414 T are pivoted upwards thereby puncturing a breakable seal on the bottom, roof-facing side of sealant cartridge  415 . Guide base  414  may also include one or more vertical tabs around its perimeter and/or coupling features  414 G that interface with an outer lip along the bottom of sealant cartridge  415  to hold sealant cartridge  415  in place both during transit and installation. It is appreciated that any of the above described features can be used separately from the other features described or can be incorporated into any of the other embodiments described herein. 
         [0079]    As with sealant cartridge  315 , sealant cartridge  415  may include center hole  416  and multiple pins  417  that can mate with reciprocal openings in compressing plate  420  and can be attached by various means, such as heat staking or another suitable bonding process. These features enable base assembly  410  to be shipped as a single integrated product. Sealant ring  411  may be adhered to the under side (e.g., roof-facing side) of compressing plate  420  using glue or other adhesive so that when compressing plate is compressed toward the roof during installation, sealant ring  411  creates a perimeter around guide base  414  to contain the flow of sealant under base assembly  410 . 
         [0080]    The embodiments of the present inventions are not to be limited in scope by the specific embodiments described herein. For example, although many of the embodiments disclosed herein have been described with reference to composite shingle roofs, the principles herein may be equally applicable to other types of roofs. Indeed, various modifications of the embodiments of the present inventions, in addition to those described herein, will be apparent to those of ordinary skill in the art from the foregoing description and accompanying drawings and claims. Thus, such modifications are intended to fall within the scope of this invention. Further, although some of the embodiments of the present invention have been described herein in the context of a particular implementation in a particular environment for a particular purpose, those of ordinary skill in the art will recognize that its usefulness is not limited thereto and that the embodiments of the present inventions can be beneficially implemented in any number of environments for any number of purposes. Accordingly, this disclosure should be construed in view of the full breath and spirit of the embodiments of the present inventions as disclosed herein and claimed below.