Tile replacement solar mounting system

• US 10,601,362 B2
• Filed: 09/07/2017
• Issued: 03/24/2020
• Est. Priority Date: 09/09/2016
• Status: Active Grant

• Current Assignee: Pegasus Solar Inc.
• Original Assignee: Pegasus Solar Inc.
• Inventors: Stephan, Erich Kai, Harris, Glenn
• Primary Examiner(s): Maestri, Patrick J
• Assistant Examiner(s): Sadlon, Joseph J.
• Application Number:
  US15/698,521
• Publication Number:
  US 20180076756A1
• Time in Patent Office: 929 Days
• Field of Search: 521733, 24822341, 24822511, 248237, 24829721
• CPC Class Codes: F16B 21/02 Releasable fastening devices locking by rotation with snap-action F16B21/06; studs or coupling pins with resilient protrusions F16B21/08
• CPC Class Codes: F16B 5/0225 allowing for adjustment parallel to the plane of the plates
• CPC Class Codes: H02S 20/23 specially adapted for roof structures
• CPC Class Codes: H02S 20/25 Roof tile elements
• CPC Class Codes: H02S 30/00 Structural details of PV modules other than those related to light conversion semiconductor device aspects of modules of electrolytic light sensitive devices H01G9/20, of inorganic PV modules H01L31/00, of organic PV modules H10K30/00
• CPC Class Codes: H02S 30/10 Frame structures
• CPC Class Codes: H02S 40/00 Components or accessories in combination with PV modules, not provided for in groups H02S10/00 - H02S30/00
• CPC Class Codes: Y02B 10/10 Photovoltaic [PV]
• CPC Class Codes: Y02E 10/50 Photovoltaic [PV] energy

Abstract

A solar panel mounting system for use on flat and “S” tile roof structures includes a support arm coupled to a threaded post. A base flashing and corresponding attachment bracket are configured to couple with the post. A tile replacement flashing is installed over the base flashing and includes a conical protrusion with associated aperture. The aperture is configured to receive the post.

Claims

1. A solar panel mounting assembly comprising:

an attachment bracket having at least one flat section and a raised section, wherein the raised section includes a post slot;

a post with a first internal threaded section on a first terminal end of the post and a second threaded section on a second terminal end of the post;

a threaded T-bolt coupling mechanism, the threaded T-bolt cooperating with the first internal threaded section and configured to traverse the post slot of the attachment bracket and couple the post with the attachment bracket; and

a tile replacement flashing having a top surface and at least one side surface defining a cavity opposite the top surface, wherein the top surface includes a conical protrusion extending away from the top surface, the conical protrusion including an aperture configured to allow the post and the threaded T-bolt to traverse therethrough.

2. The solar panel mounting assembly of claim 1, further comprising at least one attachment aperture along a length of the flat section of the attachment bracket, wherein the at least one attachment aperture comprises an extended aperture configured to receive a fastener.

3. The solar panel mounting assembly of claim 2, further comprising:

a base flashing having a substantially flat surface, at least one through-hole, and a ridge feature, wherein the base flashing is configured to be installed on an installation surface such that the ridge feature is configured to protect the at least one through-hole from moisture flowing down an installation surface towards the at least one through-hole, and wherein the at least one through-hole is configured to align with the at least one attachment aperture when the attachment bracket is adjusted on the base flashing.

4. The solar panel mounting assembly of claim 3, wherein the ridge feature is configured in a chevron shape with a peak of the chevron shape being at a distance further away from the at least one through-hole than a distance away from an arm of the chevron shape.

5. The solar panel mounting assembly of claim 3, wherein the ridge feature is configured as a triangular ridge extending away from the substantially flat surface.

6. The solar panel mounting assembly of claim 1, wherein the post slot extends a length of the raised section of the attachment bracket.

7. The solar panel mounting assembly of claim 1, wherein the raised section of the attachment bracket is raised in only a portion of the length of the attachment bracket.

8. The solar panel mounting assembly of claim 1, wherein the post further includes an exterior non-threaded section between the first terminal end and the second terminal end.

9. The solar panel mounting assembly of claim 1, wherein the second threaded section on the second terminal end of the post is an internal threaded section.

10. The solar panel mounting assembly of claim 1, wherein the second threaded section on the second terminal end of the post is an external threaded section.

11. The solar panel mounting assembly of claim 1, wherein the tile replacement flashing includes at least one downward protruding face at a corner of the flashing formed without an aperture at the corner and stiffening ribs are formed into the top surface for rigidity.

12. The solar panel mounting assembly of claim 1, wherein a first dimension of the aperture is larger than a second dimension of the threaded T-bolt coupling mechanism and a cross-sectional dimension of the post such that the threaded T-bolt coupling mechanism and post freely fits through the aperture.

13. The solar panel mounting assembly of claim 1, further comprising a rubber boot configured to seal the aperture from moisture entering the aperture when the post is inserted therethrough.

14. The solar panel mounting assembly of claim 1, further comprising:

a support arm assembly having an internal threading and an arm, the internal threading of the support arm cooperating with the second threaded section on the second terminal end of the post; and

a mounting clamp assembly having a top clamp and a bottom clamp, wherein the top clamp is installed on the support arm assembly when a fastener is inserted through the top clamp, the bottom clamp, and tightened with a fastener nut.

15. The solar panel mounting assembly of claim 1, further comprising:

an extender arm having an internal cavity for mating with the post, an extension section, and a vertically protruding threaded post.

16. The solar panel mounting assembly of claim 15, wherein the extension section is a sloping extension section that slopes down away from the first internal threaded section, and wherein the vertically protruding threaded post is configured with a height that brings vertically protruding threaded post to a top height of the first internal threaded section.

17. The solar panel mounting assembly of claim 1, wherein the conical protrusion prevents water from entering the aperture.

18. A solar panel mounting assembly comprising:

an attachment bracket having at least one attachment aperture and a post slot along a length of the attachment bracket;

a post with an internal threaded section on a terminal end of the post;

a threaded T-bolt, the threaded T-bolt cooperating with the internal threaded section of the post and configured to traverse the post slot of the attachment bracket and couple the post with the attachment bracket; and

a tile replacement flashing having a top surface and at least one side surface defining a cavity opposite the top surface, wherein the top surface includes a conical protrusion extending away from the top surface, the conical protrusion including an aperture configured to allow the post and the threaded T-bolt to traverse therethrough.