Systems and methods for mounting roof-mounted photovoltaic arrays including flashing and adhesive pads

A system for flashing a mount of a photovoltaic assembly on a surface includes a flashing including a lower surface and an upper surface. The flashing defines an opening to receive a fastener for securing the mount to the surface. The system also includes a first pad positioned along and attached to the lower surface and a second pad positioned along and attached to the upper surface. The first pad and the second pad extend across the opening. The first pad and the second pad include an adhesive and form a water resistant seal for the opening.

FIELD

This disclosure generally relates to flashing mounting systems for roofs and, more specifically, to flashing mounting systems for roof-mounted photovoltaic arrays.

BACKGROUND

Photovoltaic (PV) modules may be mounted to a surface of a structure such as a roof to form PV arrays. Each PV module may be mounted to the surface by mounts that secure the PV module to the surface and elevate the PV module above the surface. Sometimes, securing each mount to the surface causes one or more penetrations in the surface. Typically, photovoltaic arrays require numerous mounts and, thus, numerous penetrations in the surface. However, such penetrations may need to be sealed to prevent water intrusion into the structure through the penetrations. For example, flashing may be positioned on the mounts and the surface may be sealed using sealant materials. Sometimes, seals such as grommets may be used to seal openings in the flashing. However, the grommets require pressure to inhibit water intrusion through the openings and may deteriorate over time. Also, seals or barriers may be positioned to direct water flow away from the opening. However, the water may travel around the seals or barriers and through a drainage path towards the opening. In addition, forces such as wind can cause water to move upwards and overcome raised seals or barriers. Accordingly, such seals and barriers may not completely and reliably prevent water intrusion into the structure through the penetrations.

At least some flashing may be specially designed for use with the mounts. For example, some flashings include a raised interface to inhibit water flow into the penetrations. However, the raised interface increases the cost of materials and time required to assemble the flashing and requires the mount to have an increased size. The increased size or height of the mount increases the height of the entire PV array and increases the space between the PV array and the roof surface which can affect the aesthetics of the system. In addition, some flashings include an additional support to accommodate a seal, which further increases the cost to assemble the systems. Also, the flashing may experience stresses and deform when the flashing is connected to the surface.

Accordingly, there is a need for a system that simplifies the process to mount photovoltaic arrays and provides a reliable and robust water-resistant seal for penetrations.

BRIEF DESCRIPTION

In one aspect, a system for flashing a mount of a photovoltaic assembly on a surface includes a flashing with a lower surface and an upper surface. The flashing defines an opening to receive a fastener for securing the mount to the surface. The system also includes a first pad positioned along and attached to the lower surface and a second pad positioned along and attached to the upper surface. The first pad and the second pad extend across the opening. The first pad and the second pad include an adhesive and form a water resistant seal for the opening.

In another aspect, a system for flashing a mount of a photovoltaic assembly on a surface includes a flashing with a lower surface and an upper surface. The flashing defines an opening to receive a fastener for securing the mount to the surface. The system also includes a seal extending around the fastener when the fastener is positioned in the opening. The seal provides a first barrier to inhibit water intrusion through the opening. The system further includes a pad attached to one of the lower surface and the upper surface, wherein the pad provides a second barrier to inhibit water intrusion through an interface of the flashing and the surface.

In yet another aspect, a system for flashing a mount of a photovoltaic assembly on a surface includes a flashing with a lower surface and an upper surface. The flashing defines an opening to receive a fastener for securing the mount to the surface. The system also includes a pad disposed on one of the lower surface and the upper surface by adhesive. The pad is compressible and provides a seal to inhibit water intrusion through the opening.

In another aspect, a system for flashing a mount of a photovoltaic assembly on a roofing surface includes a flashing with a lower surface and an upper surface. The flashing defines an opening to receive a fastener for securing the mount to the surface. The system also includes a pad attached to the lower surface by adhesive. The pad is U-shaped and provides a barrier to inhibit water intrusion between the roofing surface and the lower surface of the flashing.

DETAILED DESCRIPTION

FIG. 1is a perspective view of an as installed system100for mounting photovoltaic modules and support structures. The system100includes a mount104, a fastener110, a sealing washer150, and a flashing assembly106.FIG. 2is an exploded perspective view of the system100including the flashing assembly106.FIG. 6is a sectional view of the as installed system100for mounting photovoltaic (PV) modules and photovoltaic support structures on a surface102of a structure. The structure may be, for example, a building having a sloped or flat roof or any other structure suitable for mounting PV modules. In the example, the structure is a roof and includes shingles115and supports117.

FIG. 3is an exploded perspective view of all the components of the system100prior to assembly.FIG. 4shows the perspective view of the flashing assembly106.FIG. 5shows an exploded view of the flashing assembly106. The flashing assembly106includes a flashing108, a first pad118, and a second pad120. A second release sheet142may cover a second attachment surface124of the first pad118and a fourth release sheet146may cover a fourth attachment surface128of the second pad120. The release sheets142,146may be shipped with the flashing assembly106to protect the attachment surfaces124,128until the attachment surfaces124,128are exposed during installation of the system100. In addition, the release sheets142,146may prevent the first pad118and the second pad120from sticking to adjacent flashing assemblies106when multiple flashing assemblies are packaged together.

In the example, the mount104is a bracket. Fasteners110are secured through the mount104, the flashing assembly106, and into the supports117of the structure. In other embodiments, the system100may include any mount104and/or combination of fasteners110that enables the system100to operate as described.

As an example, embodiments of the systems and methods are described in the context of PV modules. However, the flashing assemblies106may be used to flash any penetrations in surfaces. For example, the described embodiments may be used for penetrations in roofs such as penetrations for heating, venting, and air-conditioning systems, plumbing vents, chimneys, mechanical attachments, and any other components requiring penetrations in roofs. The term “penetration” refers to an opening in a surface.

The flashing assembly106may be connected to the mount104and positioned over any openings in the surface102. As described further below, the flashing assembly106includes one or more sticky pads118,120to provide a water-resistant seal for any penetrations in the surface. The pads118,120are sticky, i.e., the pads118,120attach to surfaces. As used herein, the term “sticky” refers to a tendency to attach to surfaces. The pads118,120provide a robust seal between surfaces and completely seal the penetrations in the surface102. In contrast, known systems form a torturous or raised path for the water. The pads118,120provide a seal without requiring the torturous or raised path. In addition, the pads118,120may attach to all surfaces in the system100and provide a seal without requiring a constant pressure. As a result, the embodiments decrease the number of parts and the part complexity required to provide a water-resistant seal. In addition, the pads118,120maintain a seal for a longer time than systems that require pressure to be applied constantly to maintain the seal.

As shown inFIG. 6, when the mount104is secured to the surface102, a PV module286may be attached directly to the mount104. In another example, a rail or support structure282may be attached to the mount104by a fastener284and one or more PV modules286may be attached to each rail282by a fastener288. In other embodiments, the PV modules286may be mounted in any manner that enables the PV module to function as described. For example, the PV module286and/or the rail282may be directly attached to the mount104. In addition, each PV module may be attached directly or indirectly to a plurality of mounts104.

Referring toFIG. 2, the flashing assembly106includes flashing108and pads118,120. The flashing108includes a lower surface112and an upper surface114. The flashing108may be positioned between layers of the surface102as shown inFIG. 6. For example, in this embodiment, the flashing108extends between shingles115of the surface102in an overlapping arrangement. In some embodiments, the pads118,120allow the flashing108to be positioned on the top of surface102because the pads118,120provide a water-resistant seal without requiring an overlap of the surface102and the flashing108. As shown inFIG. 2, the flashing108defines an opening116to receive a fastener110for securing the mount104to the surface102.

With reference toFIGS. 2 and 3, a first pad118is attached to the lower surface112and a second pad120is attached to the upper surface114. The first pad118and the second pad120extend across and completely cover the opening116on opposite sides of the flashing108. Moreover, the first pad118and the second pad120contact each other at the opening116and bond together to form a unitary structure. As a result, the first pad118and the second pad120seal the opening116. Accordingly, the flashing assembly106is configured to receive fasteners110but does not include any unsealed openings. In contrast, known systems include unsealed holes that receive fasteners and must be sealed after installation. In the example, the first pad118and the second pad120form a membrane that must be penetrated by the fastener110and that automatically forms a seal around the fastener110when the fastener110is positioned in the opening116.

In addition, the first pad118and the second pad120attach to the fastener110when the fastener110extends through the opening116. The first pad118and the second pad120may be pulled into the penetration in the surface102and seal the penetration when the fastener110is secured to the surface102. Accordingly, the first pad118and the second pad120provide a water-resistant seal for the opening116and between the flashing assembly106and the surface102and the supports117. Also, the flashing assembly106does not require any field applied sealant to ensure water resistance at the penetration when the mount104is secured using the fastener110. In contrast, known systems require sealant to be field applied to produce a proper water resistant penetration. In other embodiments, the flashing assembly106may include any pad118,120that enables the flashing assembly106to function as described. For example, in some embodiments, one or more pads118,120may be positioned on the lower surface112and/or the upper surface114.

The flashing108may be any shape and size. In this embodiment, the flashing108is a rectangle and is planar. The flashing108may include any materials including, for example and without limitation, metals, polymeric materials, and rubber. In other embodiments, the flashing assembly106may include any flashing108that enables the flashing assembly106to function as described.

The pads118,120allow the opening116to be oversized because the pads118,120completely seal the opening116. Specifically, the opening116may have a diameter that is greater than the diameter of the fastener110. The diameter of the opening116may be greater than the diameter of the fastener110by a percentage of the diameter of the fastener110in a range of about 10% to about 1,000%, or about 15% to about 50%. In the example, the diameter of the opening116is at least 20% greater than the diameter of the fastener110. In contrast, current systems include openings that are sized to tightly fit the fasteners110because any excess space must be sealed after the fastener110is installed.

Accordingly, in this embodiment, the fastener110does not have to be positioned precisely to fit into the opening116and align the fastener110with the target location on the surface102. The target location can be defined by a pilot hole or by some other means. As a result, the time required to secure the system100and the flashing assembly106to the surface102is significantly reduced compared to previous systems where near perfect alignment between the opening and the target location was required. Accordingly, the oversized opening116allows blind installation (i.e., installation without seeing the target location) and reduces the time required to search for a target location. In other embodiments, the flashing108may include any opening116that enables the flashing assembly106to function as described. For example, in some embodiments, the flashing assembly106may include more than one opening116(see, e.g., openings237shown inFIG. 14) and the pads118,120may seal each opening116. In addition, the opening(s)116can be any shape including circles, ovals, slots, rectangles, trapezoids, pentagons, hexagons, and/or shapes including any number of sides and each opening may receive more than a single fastener.

FIG. 5is an exploded view of the flashing assembly106. The flashing assembly106includes a first pad118and a second pad120. The first pad118has a first attachment surface122and a second attachment surface124opposite the first attachment surface122. The second pad120has a third attachment surface126and a fourth attachment surface128opposite the third attachment surface126. Accordingly, the first pad118and the second pad120are double-sided adhesive pads.

Prior to installation of the flashing assembly106, the first attachment surface122may be attached to the lower surface112of the flashing108and the third attachment surface126may be attached to the upper surface114. Accordingly, the flashing108is “sandwiched” between the first pad118and the second pad120. To attach the flashing assembly106to the surface102and to the mount104, the second attachment surface124may be attached to the surface102and the fourth attachment surface128may be attached to the mount104. In other embodiments, the first pad118and the second pad120may be attached to the flashing108, the mount104, and/or the surface102in any manner that enables the flashing assembly106to function as described.

The first pad118and the second pad120may be a free form adhesive such as a sticky putty or a butyl type tape. In the example, the first pad118and the second pad120are made entirely of an adhesive material. In other embodiments, the pads118and120may be a rubber, foam, and/or other polymeric material. In other embodiments, adhesives may be included on one or both sides of the pads118,120. For example, the pads118,120may include an adhesive on the attachment surfaces122,124,126,128that is configured to attach to the flashing108, the mount104, and the surface102(shown inFIG. 6). In addition, the first pad118may be designed to seal asphalt, asphalt shingles, concrete tiles, clay tiles, rubber, modified bitumen roofing underlayments, roofing membranes such as TPO (thermoplastic polyefin), EPDM (ethylene propylene diene terpolymer), PVC (polyvinyl chloride), and/or any other roofing surface. In other embodiments, the flashing assembly106may include any pad118,120that enables the flashing assembly106to function as described.

In another embodiment, the first pad118and the second pad120may not be attached to the flashing108to form the flashing assembly106prior to installation of the flashing assembly106. For example, the first pad118and the second pad120can be shipped with or separately from the flashing108and be attached to the flashing108during installation of the system100. To prevent the first pad118and the second pad120from attaching to materials prior to installation, the first pad118and/or the second pad120may be protected by release sheets as shown inFIG. 3. For example, the first pad118and the second pad120may be protected by a first release sheet140, a second release sheet142, a third release sheet144, and a fourth release sheet146(shown inFIG. 3). The first release sheet140may be positioned on the first attachment surface122and the second release sheet142may be positioned on the second attachment surface124of the first pad118. The third release sheet144may be positioned on the third attachment surface126and the fourth release sheet146may be positioned on the fourth attachment surface128of the second pad120. The first release sheet140may be removed from the first attachment surface122and the third release sheet144may be removed from the third attachment surface126to allow the first pad118and the second pad120to attach to the flashing108and form the flashing assembly106.

In reference toFIG. 5, the second release sheet142may remain over the second attachment surface124to prevent objects attaching to the second attachment surface124prior to installation of the flashing assembly106. The fourth release sheet146may remain over the fourth attachment surface128to prevent objects attaching to the fourth attachment surface128prior to installation of the flashing assembly106. In this embodiment, each release sheet140,142,144,146may comprise a plastic or non-adhesive sheet that covers the attachment surfaces122,124,126,128. In some embodiments, the release sheets142,146may include a grip or tab to facilitate removal of the release sheets142,146as shown inFIG. 20.

FIG. 20is a top view of the flashing assembly106with a pull-tab262. As shown inFIGS. 21 and 22, the pull-tab262includes an adhesive surface266that sticks to the top or the exposed surface of the release sheets142,146and a non-adhesive section264that may be grasped by the installer to remove the release sheets142,146.FIG. 21is a partially exploded perspective view of the flashing assembly106shown inFIG. 20.FIG. 22is a fully exploded perspective view of the flashing assembly106shown inFIGS. 21 and 22and showing release sheets142,146. The pull-tabs262allow for easy removal of the release sheets142,146from the first and second pads118,120because the pull-tabs262provide a location for the installer to grasp without contacting adhesive. Accordingly, the pull-tabs262allow the pads118,120to include sticky materials with increased waterproof capabilities without the installer's fingers sticking to the pads118,120. As a result, the pull-tabs262reduce the time and materials required to install the system and reduce the possibility of damage to the pads118,120during removal of the release sheets142,146.

In another embodiment, the release sheet142,146may be oversized relative to the respective attachment surfaces124,128such that a portion of the release sheet is exposed for a user to grasp. Besides allowing for easy release, the oversized release sheets142,146may cover the edges130of the pad118,120that can stick to other surfaces or to other flashing assemblies106when the flashing assemblies106are packaged.

In another embodiment shown inFIGS. 23, 24, and25, an oversized release sheet270can include an adhesive strip272that sticks to the second and fourth release sheets144,148. Accordingly, the oversized release sheet270can act as a pull-tab and an edge130protector.FIG. 23is a top view of the flashing assembly106with the oversized release sheet270.FIG. 24is a partially exploded perspective view of the flashing assembly106shown inFIG. 23with the second and fourth release sheets142and146attached to the pads118and120, respectively.FIG. 25is a fully exploded perspective view of the flashing assembly106shownFIG. 23.

The oversized release sheet270is rectangular and the adhesive strip272extends across a width of the oversized release sheet270. In other embodiments, the system100may include any oversized release sheet270that enables the system100to operate as described. For example, in some embodiments, the oversized release sheet270may be any suitable shape.

In another embodiment, an oversized release sheet270without the adhesive strip272is attached directly to the second and fourth attachment surfaces124and128of the first and second pads118and120. The oversized release sheets270prevent the edges130of the pads118and120from sticking to the adjacent flashing assemblies106.FIG. 27is a perspective view of the flashing assemblies106stacked for packaging with maximum density.FIG. 26is an exploded view of the flashing assemblies106shown inFIG. 27. In other embodiments, the flashing assembly106may include any release sheet140,142,144,146that enables the flashing assembly to function as described. The release sheets140,142,144,146, and270allow the first and second pads118,120to be protected and prepared prior to installation and enable the use of highly sticky materials that result in superior waterproofing performance in comparison to known systems.

In reference toFIG. 6, the first pad118and the second pad120are compressible. As used herein, the term “compressible” refers to a material that changes volume in response to changes in pressure. Suitably, the first pad118and the second pad120form a water-resistant seal when compressed. In this embodiment, the first pad118is compressed between the flashing108and the surface102when the flashing assembly106is attached to the surface102. The first pad118conforms to imperfections, to textures, and around aggregate granules in the roof surface102and adheres and seals to the surface102. The second pad120is compressed between the flashing108and the mount104when the flashing108is connected to the mount104. The second pad120conforms to, fills, and adheres to imperfections and nonuniform features of the contact surface of the mount104. In addition, the first pad118is compliant and conforms to any gap between the surface102and the flashing108to maintain the water-resistant seal when the flashing assembly106experiences deflection caused by loads on the system100. Also, the first pad118slightly raises the flashing108above the surface102after installation. This aspect removes loading on the portion of the flashing108beyond the mount that can cause the flashing108to warp which reduces the seal of the assembly. The removed loading removes the need for strengthening ribs within the flashing108or additional and expensive stabilization pucks which increase the cost of known products. As a result, the flashing assembly106provides a lower cost and simpler product with a more repeatable and robust water-resistant seal. In addition, the water-resistant seal is maintained after an initial activation pressure is removed.

The first pad118and the second pad120may have any suitable shape and size. For example, in this embodiment, the first pad118and the second pad120are rectangular. In other embodiments, the first pad118and/or the second pad120may be a square, a circle, a triangle, a trapezoid, an oval, a rectangle, a pentagon, a hexagon, or any other sided multi-sided shape. In addition, the first pad118and the second pad120are flat or planar. The first pad118and the second pad120may each have a thickness in a range of about 0.01 inches (in.) to about 0.5 in or about 0.03 in. to about 0.25 in. or about 0.03 in. to about 0.125 in. or about 0.03 in. to about 0.08 in. In other embodiments, the pads118,120may be non-planar. For example, in some embodiments, the first pad118and/or the second pad120may be conical. Also, in some embodiments, the shape of the first pad118and/or the second pad120may match the shape of the flashing108and/or the mount104to form a tortuous path, to provide a better mating surface, and/or to fill in gaps between components which inhibit water intrusion into the structure through the opening116.

In this embodiment, a sealing washer150is positioned under a head of the fastener110as shown inFIG. 2. The sealing washer150provides a seal between the fastener110and the mount104to inhibit water ingress along the fastener110. The first pad118and the second pad120also seal around the fastener110and provide a second layer of protection. Known systems rely upon the sealing washer150as the critical or only sealing component. In contrast, the first pad118and the second pad120prevent water from entering the penetration in the surface102if water flows past the sealing washer150. Accordingly, the sealing washer150is not the critical sealing component. In some embodiments, the sealing washer150may be omitted.

To install the system100, the flashing assembly106may be provided at a desired installation site in a pre-installation or first configuration. In the first configuration, shown inFIG. 4, the first pad118is attached to the lower surface112of the flashing108by removing the first release sheet140from the first attachment surface122. The second pad120is attached to the upper surface114of the flashing108by removing the third release sheet144from the third attachment surface126. An exploded view of the first configuration is shown inFIG. 5. To switch the flashing assembly106into an installation or second configuration, the second release sheet142and the fourth release sheet146are removed from the second attachment surface124and the fourth attachment surface128, respectively, as shown inFIG. 2.FIG. 3is an exploded view of all components of the system100. The flashing108is positioned along the surface102and the second attachment surface124is attached to the surface102. The flashing assembly106seals any corresponding pilot holes or penetrations in the surface102when the flashing108is attached to the surface102. Accordingly, the flashing assembly106prevents water ingress through the penetrations after the flashing108is attached to the surface102even if the installation of the system100is not immediately completed. Accordingly, in contrast to known systems, extra steps and components are not required to seal the penetrations if the installation is halted such as if the installers leave the installation site due to rain.

To secure the mount104to the surface102, the fourth attachment surface128is attached to the mount104. The fastener110is positioned through an opening in the mount104and through the opening116in the flashing108. The first pad118and the second pad120seal around the fastener110and form a water-resistant seal without requiring pressure. The fastener110is tightened and, as a result, the first pad118and the second pad120are compressed. One or more PV modules may be attached to the mount104. In other embodiments, the system100may be installed in any manner that enables the system100to operate as described. For example, in some embodiments, the first pad118and/or the second pad120may be attached to the flashing108simultaneously or after positioning the flashing108on the surface102. In other embodiments, the first pad118and/or the second pad120do not include adhesives and compression of the first pad118and/or the second pad120provides the water-resistant seal without adhesive.

FIG. 7is a perspective view of an embodiment of the system100showing the flashing assembly106including notched flashing202. The flashing202is rectangular and includes four edges204. At least one notch, broadly a location feature,206is positioned along at least one edge204of the flashing202. In the example, the flashing202includes three notches206. Each notch206is aligned with the opening (not shown inFIG. 4) of the flashing202. The notches206allow an operator to position the flashing assembly106in a target location on the surface102(shown inFIG. 6). In addition, the notches206allow the operator to align the mount104and/or the fastener110with the opening116. In other embodiments, the flashing108may include marks, projections, and/or any other suitable location features.

FIG. 8is a perspective view of an embodiment of the flashing assembly106and a mount208. The mount208includes a first plate210and a second plate212. The first plate210and the second plate212are joined along edges to form an L-shape. The first plate210includes an opening214sized to receive the fastener110. The second plate212includes a slot216sized to receive a fastener (not shown inFIG. 8) for securing a PV module and/or PV module support system to the mount208. An axis218extends along the joint between the first plate210and the second plate212. The opening214and the slot216are offset along the axis218. The offset distance between the opening214and the slot216may provide clearance for use of tools when the mount208and PV modules are secured to the surface102(shown inFIG. 6). In other embodiments, the mount208may include any openings that enable the mount208to function as described.

The first pad118and the second pad120allow the flashing assembly106to accommodate different mounts such as the mount208and the mount104(shown inFIG. 1) because the pads118,120can extend across and seal any openings in the flashing108that are provided to accommodate the different mounts104,208. Moreover, the first pad118and the second pad120may extend along only a portion of the mount208and may have a size different from the size of the mount208and/or the flashing108. Accordingly, the first pad118and the second pad120are modular and may be used with different flashing assemblies106, flashings108, and mounts104.

FIG. 9is a perspective view of an embodiment of the system100including flashing220with a raised interface222for receiving the mount104.FIG. 10is an exploded view of the system100including the flashing220.FIG. 11is a side view of the system100including the flashing220. The raised interface222raises the opening116and the mount104a distance from the planar surface of the flashing220and from the surface102(shown inFIG. 6). Accordingly, the raised interface222positions the opening116out of the path of water to inhibit water intrusion through the opening116. In some embodiments, the raised interface222may be stamped into the flashing220and define a recess on the underside of the flashing220. In other embodiments, the flashing220may include any raised interface222that enables the flashing to function as described. For example, in some embodiments, the flashing220and the raised interface222may be formed separately and attached together. In other embodiments, a block or support may be positioned on or attached to the flashing220to space the mount104from the flashing220.

In the example, a first pad224is positioned on a lower surface225(shown inFIG. 11) of the flashing220and extends into the recess of the raised interface222. The first pad224has an increased thickness in comparison to the first pad118(shown inFIG. 1). Specifically, the first pad224is sized to extend from the recess and be compressed when the flashing220is secured to the surface102(shown inFIG. 6). The first pad224is rectangular and corresponds to a shape of the recess. In addition, the first pad224extends across the opening116when the first pad224is positioned in the recess. In other embodiments, the flashing assembly106may include any first pad224that enables the flashing assembly106to operate as described. For example, in some embodiments, the first pad224is sized to extend across the opening116and does not necessarily fill or extend from the recess.

FIG. 12is a perspective view of an embodiment of the system100including the flashing226including a water deflection structure228. The water deflection structure228extends partially around the mount104and the opening116and is raised from the planar portion of flashing226. Accordingly, the water deflection structure228inhibits water from flowing towards the opening116. The water deflection structure228defines a gap230that is downslope from the opening116. Any water that is able travel upslope and through the gap230towards the opening116will be prevented from intruding into the structure through the opening116because the first pad224seals the opening116.

With reference toFIGS. 13-15, the flashing assembly106may be used with a mount232having different configurations. For example,FIGS. 13 and 14show the flashing assembly106in use with a mount232in a first, a “direct-to-deck attachment” configuration.FIG. 15shows the flashing assembly106in use with the mount232in a second, “rafter attachment” configuration. The mount232includes middle openings234and outer openings236. The middle openings234are aligned along a center axis of the mount232and receive the fasteners110when the mount232is in the second configuration. The outer openings236are spaced along the periphery of the mount104and receive the fasteners110when the mount232is in the first configuration. The mount includes two middle openings234and four outer openings236. The flashing238includes openings237. Each opening237is aligned with an opening234,236and receives the fastener110when the fastener110is positioned in the respective opening234,236. In other embodiments, the mount232and the flashing238may include any opening234,236,237that enables the system to function as described.

The first pad118and the second pad120allow the mount104to be used in the first configuration and the second configuration because the first pad118and the second pad120extend across and seal each of the openings237. Accordingly, the openings237are sealed by the first pad118and the second pad120when the fasteners110are positioned in the openings237and when the fasteners110are not positioned in the openings237. Accordingly, the first pad118and the second pad120allow the flashing assembly106to be modular and be used with different mounts104,232having different configurations. In contrast, known systems require different and/or additional components to accommodate different configurations. For example, known systems require additional components to cover the openings in the flashing and/or in the mount for any unused fastener locations.

FIG. 16is an exploded view of an embodiment of the system100including a flashing238including a raised opening240. An extension241extends from the flashing238and defines the opening240. The extension241is sized to extend into the opening in the mount104. The extension241inhibits water intrusion through the opening240. The first pad118extends between the flashing238and the surface102(shown inFIG. 6) and provides a seal on the underside of the flashing238to the surface102. In addition, the fastener110extends through the opening240, passes through the first pad118, and is sealed when the fastener110is secured to the surface102(shown inFIG. 6). Accordingly, the first pad118provides an additional and automatic double sealing (between surfaces102and flashing238and around the fastener110) which provides a more reliable seal than products with only raised openings. In other embodiments, the flashing assembly106may include any flashing238that enables the flashing assembly106to function as described.

FIG. 17is an exploded view of an embodiment of the system100including a pad248and a grommet250.FIG. 18is a perspective view of the lower surface112of the flashing108shown inFIG. 17. The grommet250is positioned at least partially in the opening116and seals around the fastener110when the fastener110is positioned in the opening116. The pad248is positioned on the lower surface112of the flashing108. The pad248defines an opening252that is aligned with the opening116in the flashing108. In addition, the opening252is larger than the opening116in the flashing108. Accordingly, the pad248accommodates the grommet250in the opening116. In addition, the pad248provides a seal between the flashing108and the surface102(shown inFIG. 6) and a raised platform to prevent flashing warpage when the fastener110is tightened to a final position. This is an improvement over known systems including grommets because the pad248provides an automatic and reliable sealing between the roofing surface102and the flashing108and removes the need for additional field applied sealant between these surfaces which is required by known systems.

FIG. 19is an exploded view of an embodiment of the system100including a first pad254on a lower surface112of the flashing108and a second pad256on the upper surface114of the flashing108. The flashing assembly106also includes the grommet250positioned at least partially in the opening116. The first pad254and the second pad256each include an opening258. The openings258are aligned with the opening116in the flashing108and are sized to accommodate the grommet250. The first pad254and the second pad256provide seals between the lower surface112and the surface102(shown inFIG. 6) and between the upper surface114and the mount104. The grommet250provides a seal around the fastener110when the grommet250and the fastener110are positioned within the opening116. In other embodiments, the flashing assembly106may include any seals that enable the flashing assembly106to operate as described. For example, in some embodiments, at least one of the first pad254, the second pad256, and the grommet250is omitted. This approach is an improvement over current systems including grommets because the flashing assembly106provides (1) a raised platform, (2) an automatic seal between the roofing surface102and the flashing108, and (3) a robust water seal between the mount104and the flashing108. Accordingly, the flashing assembly106provides an additional water seal either to supplement the grommet or replace the requirement of the grommet to provide a seal at this interface.

As shown inFIG. 28, a u-shaped pad274can be used and applied to the flashing assembly106. This provides a vast improvement to field applied sealant and will work with many current technologies to create a faster and cleaner installation and a more cost effective solution. The u-shaped pad274extends around the opening116and inhibits water intrusion into the structure through penetrations. The u-shaped pad274defines a gap down flow of the opening116to allow any water to escape. In contrast, current systems include a field-applied sealant between the surface102and the flashing108at the time of installation to prevent wind driven rain or lateral water flow from traveling under the flashing108and into the penetration in the surface. However, the systems including field-applied sealant suffer from problems of requiring additional materials and tools, the messy nature of field applied sealants, and material compatibility. The u-shaped pad274allows field-applied sealants to be omitted and is compatible with a variety of systems.

Embodiments of the methods and systems described achieve superior results compared to prior methods and systems. For example, the systems and methods described provide a complete water-resistant seal for a flashing assembly. In addition, the embodiments simplify the installation of PV modules on structures. More specifically, the embodiments reduce the labor, tools, and materials required for creating a water-resistant seal on a surface at the mount locations of the PV modules. Also, the systems and methods described may provide a more robust and consistent seal at each mount location.

In addition, embodiments of the methods and systems described can be used with different mounts and different attachment configurations because the pads seal all openings in the flashing. Accordingly, the embodiments reduce the cost to install flashing and reduce the risk of failures and leaks of the flashing. Also, the embodiments may reduce the training and/or experience required to properly install the flashing.

Embodiments of the described methods and systems are not limited to use with photovoltaic assemblies. Rather, embodiments of the methods and systems described may be used for flashing assemblies on any roofing surface. For example, the methods and systems may be used for penetrations in roofs such as vents and/or mechanical attachments that extend through the roof.