Patent ID: 12258993

DETAILED DESCRIPTION OF THE INVENTION

In the following description, and for the purposes of explanation, numerous specific details are provided to thoroughly understand the various aspects of the invention. It will be understood, however, by those skilled in the relevant arts, that the present invention may be practiced without these specific details. In other instances, known structures and devices are shown or discussed more generally in order to avoid obscuring the invention. In many cases, a description of the operation is sufficient to enable one to implement the various forms of the invention, particularly when the operation is to be implemented in software. It should be noted that there are many different and alternative configurations, devices, and technologies to which the disclosed embodiments may be applied. The full scope of the invention is not limited to the example(s) that are described below.

FIGS.1-3illustrate a typical existing solar panel array structure.FIG.1shows a typical shingle roof600with several flashings630installed with a receiver640.FIG.2illustrates how an L-shaped bracket650is secured directly to the flashing630.FIG.3shows a front view of a rail-guide secured to multiple L-shaped brackets650. The figure also includes examples of a receiver640can be utilized to raise the level of where the L-shaped bracket650interfaces with the flashing and the roof. The bracket650is then generally secured to a rail guide620by using a standard nut and bolt combination as shown, which is then used to support an end clamp660. The end clamp660is then coupled to a solar panel module610as shown.

FIG.4shows an exemplary embodiment of the present invention that overcomes the limitations of the prior art. A mounting bracket100is shown. The mounting bracket100is an improvement over the L-shaped bracket shown inFIGS.1-3. The bracket100has a base110. A typical base is cylindrically shaped as shown, but the base110is not limited to a round shape. The base110tapers upward and forms a generally U-shaped guide130that forms a pair of members103extending from opposing sides of the base110, which in turn forms an aperture135. Aperture135also includes a recessed path101that terminates at a lip100A.FIG.5shows how once a fastener such as nut and bolt140is dropped into the aperture135, the path101allows the nut and bolt140to move along the path101, but the lip100A prevents the edge of the bolt140A from slipping out of the aperture135. Each side of the guide130also includes ridges120.

FIG.5illustrates in greater detail how the bracket100is coupled to an alternate embodiment of a rail guide200similar to the support620shown inFIGS.2and3. This particular rail guide200includes a bolt slot210. The bracket100is typically coupled to the rail guide200by using the nut and bolt combination140. The guide130allows the nut and bolt combination140to be inserted downward at the top of the open end of the aperture135between the nut and the rail support200with the nut already partially tightened as shown inFIG.5. The symmetrical shape of the bracket100and the existence of a recessed path101and lip100A on both sides of aperture135also allows the bracket100to be coupled to the rail-guide210from either side of the guide130. The length of the aperture135allows the rail guide200to be adjusted at various heights. Other similar shapes can be used for the guide130such as one that is closed on all sides. A closed configuration, however, would require that the bolt be inserted through the aperture135prior to affixing the nut. The ridges120typically provide increased friction between the nut and the guide130to prevent the rail support200from slipping

FIG.6shows a transparent side view of the base110. A threaded link150is present in an internal or hollow opening of the base110. The threaded link150is typically a female threaded portion that will be used to secure the base110to a receiver315to be discussed inFIG.8. The threaded portion is not limited to a female threaded portion. It could also be a male threaded portion that fits to a female receiver, or it could also be another suitable connector like a bayonet-type of connector such as that shown inFIG.6A.FIG.7shows a top view of the bracket100showing how the bracket100can be turned in the clockwise direction to secure it to the receiver315as shown inFIG.8. This embodiment of the threaded link150shows a four-start thread that typically requires a 180-degree rotation for full installation. This simplifies installation and allows for multiple orientations of rail guides on the roof. Other similar thread configurations can also be used.

FIG.8shows an exemplary receiver315. The receiver315is typically embedded or secured at a raised portion of the flashing300that forms a raised base310as shown inFIG.11. The raised base310raises the level of the receiver315so that liquids or moisture will not accumulate where the receiver315is located. This elevates the roof penetration point above the roof's surface to prevent water damage and leakage. The receiver315also includes a threaded portion320, a snap tab330, and an opening340. The threaded portion320preferably should include male threads that can be used to join the base110of the bracket100to the receiver315. The snap tab330provides an exemplary means for providing an audible or tactile notification that the bracket100has been locked to the receiver315.

FIG.9shows a perspective close-up internal view of the threaded link150of the base110. Bumps165are present on the rim167of the base110.FIG.10shows a similar view to that ofFIG.9. InFIG.10, a view of a typical receiver315threaded portion320is fully inserted into the threaded link150. This is typically accomplished by rotating the bracket100in a clockwise direction around the threaded portion320until it is locked in place. Prior to the bracket100being fully engaged with the receiver315, the bumps165will engage the snap tabs330and then snap in place.

FIG.9Ashows an alternate embodiment of the snap tabs330and bumps165. A raised edge168inside the hollow opening of the base110engages and snaps over a protrusion169on the receiver315. In this case, the raised edge168inside the base110as shown inFIG.9Bis a separate component such as a retaining ring like a circlip, which is the ring-shaped portion shown in the figure. This combination provides a tactile or audible indication when the bracket100is properly coupled to the receiver315. The raised base310terminates toward the opening340by forming a vertical edge302. The vertical edge302may also taper inward toward the opening340.

FIGS.11-15illustrate the steps used to join the bracket100to the receiver315and install the flashing300to the roof600.FIG.11shows an exploded view of the combination flashing and bracket assembly with flashing300, which is generally a flat, rectangular-shaped metallic structure, although other suitable shapes and materials would work as well. The flashing300comprises a receiver315that is either embedded or secured with the flashing300along a raised base310on the flashing300. A bolt125is used to secure the flashing300to the roof600by inserting the bolt125through the opening340. The bracket100is also shown.FIG.12shows the bracket100secured to the receiver315and the flashing300presumably secured to the roof600as the bolt125has been inserted through the opening340.FIG.13shows the first step to assembling the flashing300to the roof600. One side of the flashing300is typically inserted between the shingles615on the roof600.FIG.14illustrates the next step, which is to secure the flashing300to the roof600by inserting the bolt125through the opening340of the receiver315and rotating the bolt125until it is fully tightened.FIG.15shows the final step, which is to engage the bracket100with the receiver315and rotate the bracket100clockwise along the threaded portion320until it is locked into place, which is apparent when the bumps165snap into place on the snap tabs330or when the circlip168engages the receiver315causing a tactile snap to occur and making an audible sound.FIG.16shows a sectional view of the fully assembled bracket/flashing combination where the internal elements can be seen.

FIG.17illustrates a cross-sectional side view showing how the fully assembled flashing combination beneath the capped bracket100is sealed to prevent moisture from entering the roof600. A load distribution plate350is provided between the flashing300and the roof600. The load distribution plate350is typically made of a metallic material, but any suitable material capable of distributing the load from the solar array to the roof would be sufficient. The load distribution plate350also is tightly joined to the flashing300at its raised base310, and receiver315. The interference fit between these slightly tapered parts creates a watertight seal. A washer126is also provided between the top of the bolt125and the top of the receiver315to further prevent moisture from seeping inside the opening340of the receiver315.FIGS.18and19show an exemplary method for making the receiver315water tight by using a press fit manufacturing process. As shown inFIG.18, prior to press fitting, the load distribution plate350has not yet been inserted into the receiver315as evidenced by a first gap173and a second gap303. The opening in the flashing300is supported and sealed by pressing the receiver315and load distribution plate350together with the flashing300and raised base310, which also includes the vertical edge302(also shown inFIG.9B) in between the distribution plate350becomes fully inserted into the gaps173and303to seal off any available internal openings as shown inFIG.19.

FIG.20illustrates an exploded view of another exemplary alternate embodiment of the invention. In this embodiment, a separate flashing301and a foundation305is shown and can provide a more simplified installation when the solar panel array is being assembled by multiple installers who carry out each step in an “assembly line” type of process. This embodiment also moves the roof penetration point so it is upward on the roof from the aperture309in the flashing300. This prevents water damage and leakage. The foundation305includes a hole306for receiving the bolt125on one end with the receiver315on the other end. A washer126, which may be a bonded washer, is included between the receiver315and the bolt125to provide a seal over the hole306to prevent moisture from entering the roof. The flashing301includes a raised molding308that fits to the contour of the foundation305and provides an aperture309that allows the receiver315to fit through.FIG.21shows an assembled version of the embodiment where the bracket100is secured to the receiver315.

FIG.22shows how the embodiment is assembled. First, the foundation305is properly aligned to the proper location as shown. The bolt125is inserted through hole306. As shown inFIG.23, in the next step the flashing301is inserted beneath the shingles615on one end, and the other end of the flashing301is lowered and fitted so that the molding308fits on top of the foundation305so that the receiver315fits through the aperture309.FIG.24shows the final step, which is to secure the bracket100to the receiver315by engaging the base110on the threaded portion320of the receiver315is fully accessible. The bracket100is then rotated clockwise until it is fully tightened and snaps into place as described in the previous embodiment above.FIGS.24A and24Billustrate cross-sectional views of the fully assembled embodiment as shown inFIG.24from both a side and perspective view respectively.

FIG.24Cillustrates a section view of an alternate exemplary embodiment of the invention. In this embodiment, the receiver315and load distribution plate350are one piece that is welded to the raised base310of the flashing300. The embodiment is installed using the same steps as the embodiment described inFIGS.11-15. In this embodiment, the receiver315is fit through the flashing300as shown in the cross-sectional side view ofFIG.24Dso that the base310is sealed to the receiver315using, for example, a weld357such as a laser weld, during the manufacturing process as shown in the perspective view ofFIG.24E.

FIG.24Fshows another alternate exemplary embodiment of the present invention. In this embodiment, the receiver and load distribution plate combination356is typically a polymer that is molded directly onto the flashing300. The embodiment is installed using the same steps as the embodiment described inFIGS.11-15. The cross-sectional side view provides a view the internal aspects of the embodiment. The molding of the combination356to flashing300creates a single part with a raised and supported seal that replaces the need for a pressed seal inFIGS.18-19or a welded seal inFIGS.24D-24E.

FIG.25illustrates another alternate exemplary embodiment of the present invention. The figure shows a rail-less pivot mount400with the solar panel module support500that is fully assembled to the flashing300, which is assembled to a roof600. The pivot mount400is coupled to a sealing700that is shown inFIG.26. The sealing700is an alternate exemplary embodiment of the assembled flashing combination as shown inFIG.19and is typically the cylindrically shaped member that a rail-less pivot mount is coupled to as discussed below.FIG.26illustrates a cross-sectional side view of the sealing700. The sealing700includes a generally cylindrical-shaped fitting720, a load distribution plate350. A bonded washer126is shown as an added weather barrier that includes an opening715. The washer126, the fitting720, and the distribution plate350are aligned along a central axis to form a single aperture740.FIG.27shows a cross-sectional side view that demonstrates how the sealing700is manufactured. As shown, the fitting720, and the distribution plate350are all press fit together under compression so that the base310of the flashing300is sealed between the fitting720and the distribution plate350. The fitting720and the distribution plate350include tapered portions731with pocketed walls so that the upper portion of the base310can flow into these areas when the parts are press fit together.FIG.28shows a cross-sectional side view of a fully assembled sealing700after its components have been press fit. Other suitable techniques to manufacture the sealing700could also be used as well.FIG.29shows a perspective cross-sectional view of the view inFIG.28.FIG.30shows a perspective view of the outer perimeter of the sealing700that is fully assembled with washer126placed into the top opening of the fitting720.

FIG.31shows a perspective view of how the flashing300is assembled to the roof600. The hanger bolt125A with a bonded washer126, is inserted through the aperture740in the sealing700. Once the flashing300is secured to the roof600, the rear of the pivot mount400is lowered on to the fitting720as shown in the perspective view ofFIG.32. The pivot mount400is then secured to the sealing700by using a nut770. The nut770is rotated clockwise on top of the second hanger bolt125A until it is tightened in place.FIG.34shows a sectional view of a fully assembled pivot mount400to the sealing700that is secured by the utilizing the nut770. The solar panel module support500can then receive a pair of solar panel modules to utilize a rail-less system to install the solar panel array.