Apparatus and methods for mounting a photovoltaic module on a roof

• US 8,567,154 B2
• Filed: 02/28/2012
• Issued: 10/29/2013
• Est. Priority Date: 02/28/2012
• Status: Active Grant

• Current Assignee: Johns Manville Corporation (Berkshire Hathaway Incorporated)
• Original Assignee: Johns Manville Corporation (Berkshire Hathaway Incorporated)
• Inventors: Babineau, Francis John Jr., McGraw, Ethan Nelson, Aseere, Lester Mickel
• Primary Examiner(s): Gilbert, William
• Assistant Examiner(s): FORD, GISELE D
• Application Number:
  US13/406,678
• Publication Number:
  US 20130220395A1
• Time in Patent Office: 609 Days
• Field of Search: 521/733, 527/471, 136/244, 126/621, 126/622, 126/623
• US Class Current: 52/747.1
• CPC Class Codes: F24S 2025/6008 by using toothed elements
• CPC Class Codes: F24S 2080/015 Plastics
• CPC Class Codes: F24S 25/33 forming substantially planar assemblies, e.g. of coplanar or stacked profiles
• CPC Class Codes: F24S 25/35 by means of profiles with a cross-section defining separate supporting portions for adjacent modules
• CPC Class Codes: H02S 20/23 specially adapted for roof structures
• CPC Class Codes: Y02B 10/10 Photovoltaic [PV]
• CPC Class Codes: Y02B 10/20 Solar thermal
• CPC Class Codes: Y02E 10/47 Mountings or tracking
• CPC Class Codes: Y02E 10/50 Photovoltaic [PV] energy
• CPC Class Codes: Y10T 29/49355 Solar energy device making
• CPC Class Codes: Y10T 403/45 Flexibly connected rigid members
• CPC Class Codes: Y10T 403/70 Interfitted members

Abstract

Embodiments of the invention provide systems, devices, and methods for mounting a photovoltaic module to a structure, such as a roof. An embodiment of a method for mounting a photovoltaic module to a structure may include providing a photovoltaic module, a first mounting device, and a second mounting device. The first mounting device and the second mounting device may be coupled with the structure, such as a roofing membrane, so that opposing mounting channels of the respective devices face one another. The method may further include inserting a first edge of the photovoltaic module within the mounting channel of the first mounting device and inserting a second edge of the photovoltaic module within the mounting channel of the second mounting device so that the photovoltaic module is disposed between the first mounting device and the second mounting device.

Claims

1. A method for attaching a photovoltaic module to a structure comprising:

providing a photovoltaic module;

providing a first mounting device having a longitudinal length and a transverse length and including;

a top surface;

a bottom surface;

a first longitudinal edge;

a second longitudinal edge opposite the first longitudinal edge; and

a mounting channel extending along at least a portion of the first longitudinal edge;

coupling the first mounting device with the structure;

inserting a first edge of the photovoltaic module within the mounting channel of the first mounting device;

providing a second mounting device configured similar to the first mounting device;

coupling the second mounting device with the structure so that a mounting channel of the second mounting device faces the mounting channel of the first mounting device; and

inserting a second edge of the photovoltaic module within the mounting channel of the second mounting device so that the photovoltaic module is disposed between the first mounting device and the second mounting device; and

folding or rolling the first mounting device, the photovoltaic module, and the second mounting device so as to form a rolled or folded photovoltaic blanket.

2. The method of claim 1, wherein coupling the first mounting device with the structure comprises coupling the first mounting device with a roofing membrane.

3. The method of claim 2, further comprising coupling the roofing membrane to a roof or coupling the roofing membrane to a second roofing membrane of the roof.

4. The method of claim 1, wherein inserting the first edge within the mounting channel of the first mounting device and inserting the second edge within the mounting channel of the second mounting device comprises sliding the photovoltaic module longitudinally with respect to the first and second mounting devices so that the first and second edges slide within respective mounting channels.

5. The method of claim 1, wherein the first edge is inserted within the mounting channel of the first mounting device such that a gap exists between the first edge and a rear surface of the mounting channel, the gap allowing sliding expansion of the photovoltaic module within the mounting channel.

6. The method of claim 1, wherein the first mounting device further comprises a second mounting channel extending along at least a portion of the second longitudinal edge, and wherein the method further comprises:

providing a second photovoltaic module; and

inserting a first edge of the second photovoltaic module within the second mounting channel of the first mounting device so that the first mounting device is disposed between the respective photovoltaic modules.

7. The method of claim 6, wherein the first mounting device further comprises a recessed channel extending along at least a portion of the top surface, the recessed channel being disposed between the mounting channel and the second mounting channel, and wherein the method further comprises folding the first mounting device along the recessed channel.

8. The method of claim 2, wherein coupling the first mounting device with the roofing membrane comprises heat welding the first mounting device to the roofing membrane.

9. The method of claim 2, wherein coupling the first mounting device with the roofing membrane comprises adhesively bonding the first mounting device to the roofing membrane.

10. A rolled or folded photovoltaic blanket product comprising:

a photovoltaic module;

a first mounting device having a longitudinal length and a transverse length, the first mounting device being coupled with a roofing membrane and including;

a top surface;

a bottom surface;

a first longitudinal edge;

a second longitudinal edge opposite the first longitudinal edge; and

a mounting channel extending along at least a portion of the first longitudinal edge, wherein a first edge of the photovoltaic module is inserted within the mounting channel; and

a second mounting device configured similar to the first mounting device;

the second mounting device being coupled with the roofing membrane so that a mounting channel of the second mounting device faces the mounting channel of the first mounting device, wherein a second edge of the photovoltaic module opposite the first edge is inserted within the mounting channel of the second mounting device so that the photovoltaic module is disposed between the first mounting device and the second mounting device, the first mounting device, the photovoltaic module, and the second mounting device being rolled or folded to form the photovoltaic blanket product.

11. The photovoltaic blanket product of claim 10, wherein the first mounting device further comprises a second mounting channel extending along at least a portion of the second longitudinal edge, wherein a first edge of a second photovoltaic device is inserted within the second mounting channel so that the first mounting device is disposed between two photovoltaic modules.

12. The photovoltaic blanket product of claim 11, wherein the first mounting device further comprises a recessed channel extending along at least a portion of the top surface, the recessed channel being disposed between the first mounting channel and the second mounting channel.

13. The photovoltaic blanket product of claim 10, wherein the photovoltaic blanket product is attached to a roof such that at least a portion of the photovoltaic module is supported above the roof'"'"'s surface to allow air flow or water drainage under the photovoltaic module.

14. The photovoltaic blanket product of claim 10, wherein the first edge of the photovoltaic module is inserted within the mounting channel of the first mounting device so as to allow the photovoltaic module to slidingly expand or contract within the mounting channel.

15. The photovoltaic blanket product of claim 10, wherein either or both the mounting channel of the first mounting device or the mounting channel of the second mounting device comprise a plurality of teeth configured to grip the photovoltaic module to releasably secure the photovoltaic module within the channel.

16. A device for attaching a photovoltaic module to a structure comprising:

a device body having a longitudinal length and a transverse length, the device body being couplable with the structure and including;

a top surface;

a bottom surface;

a first longitudinal edge;

a second longitudinal edge opposite the first longitudinal edge;

a first channel extending along at least a portion of the first longitudinal edge, the first channel being configured so that an edge of the photovoltaic module is insertable therein to attach the photovoltaic module to the structure;

a second channel extending along at least a portion of the second longitudinal edge, the second channel being configured so that an edge of a second photovoltaic module is insertable therein to attach the second photovoltaic module to the structure; and

a third channel extending along at least a portion of the top surface, the third channel being disposed between the first channel and the second channel, wherein the device body is foldable along the third channel.

17. The device of claim 16, further comprising a plurality of teeth disposed within the first channel, the plurality of teeth being configured to grip at least one surface of the photovoltaic module to releasably secure the photovoltaic module within the channel.

18. The device of claim 16, wherein at least a portion of the photovoltaic module is supported above the structure'"'"'s surface when inserted within the device body.