Photovoltaic module mounting system

• US 9,722,532 B2
• Filed: 08/11/2015
• Issued: 08/01/2017
• Est. Priority Date: 08/11/2015
• Status: Active Grant

• Current Assignee: Tesla Inc.
• Original Assignee: SolarCity Corporation (Tesla Inc.)
• Inventors: Almy, Charles, Molina, David
• Primary Examiner(s): Michener, Joshua J
• Assistant Examiner(s): GITLIN, MATTHEW J
• Application Number:
  US14/823,927
• Publication Number:
  US 20170047884A1
• Time in Patent Office: 721 Days
• Field of Search: 521733, 52710, 52711, 136244, 136251, 248237, 248148, 24829511, 2482051, 248200, 126623
• CPC Class Codes: F16M 13/022 repositionable
• CPC Class Codes: F24S 25/60 Fixation means, e.g. fasteners, specially adapted for supporting solar heat collector modules
• CPC Class Codes: F24S 25/61 for fixing to the ground or to building structures
• CPC Class Codes: F24S 25/615 for fixing to protruding parts of buildings, e.g. to corrugations or to standing seams
• CPC Class Codes: F24S 25/636 clamping by screw-threaded elements
• CPC Class Codes: F24S 25/70 with means for adjusting the final position or orientation of supporting elements in relation to each other or to a mounting surface; with means for compensating mounting tolerances
• 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

Abstract

A photovoltaic (PV) module mounting system including a mounting bracket that has a curved mating surface extending as an arch between a pair of flat mounting feet portions. The mounting bracket supports a PV module coupling device. A hanger bolt is provided that has a first threaded portion adapted to engage a roof surface and a second threaded portion for passing through the curved mating surface of the mounting bracket. A threaded knob is adapted to mate with the second threaded portion of the hanger bolt.

Claims

1. A photovoltaic (PV) module mounting system comprising:

a mounting bracket having a first portion arranged to face a roof and a second portion arranged to face a PV array, wherein the first and second portions are spaced apart from one another and have a curved cross-sectional shape;

a pair of flat mounting feet portions on the first portion;

a first slot formed in the first portion and a second slot formed in the second portion, wherein the first slot and second slot are aligned and the second slot is larger than the first slot;

a hanger bolt comprising a first threaded portion adapted to engage a roof surface, a second threaded portion adapted to pass through the first and second slots of the mounting bracket, and a washer located between the first threaded portion and the second threaded portion for limiting a depth that the first threaded portion can achieve in the roof surface;

a threaded knob adapted to mate with the second threaded portion of the hanger bolt and to compress the mounting bracket against a roof surface when rotational torque is applied to the threaded knob; and

a PV module coupling device attached to the mounting bracket and adapted to engage frames of and maintain a space between at least two photovoltaic modules.

2. The system of claim 1, wherein the first portion of the mounting bracket comprises a first curved surface portion.

3. The system of claim 2, wherein the second portion of the mounting bracket comprises a second curved surface portion.

4. The system of claim 3, wherein a lower portion of the threaded knob abuts the first curved surface portion, and an upper portion of the threaded knob extends past the second curved surface portion, when rotational torque is applied to the threaded knob.

5. The system of claim 1, wherein the hanger bolt is configured to pass through the first and second slots of the mounting bracket at non-transverse angles with respect to the flat mounting feet portions.

6. The system of claim 1, wherein the threaded knob includes a hand grip and at least one push nut.

7. The system of claim 1, wherein the PV module coupling device comprises a rock-it connector.

8. The system of claim 1, wherein the PV module coupling device comprises a clamping connector.

9. The system of claim 1, wherein at least one rib connects the first and second portions of the mounting bracket.

10. A photovoltaic (PV) module mounting system comprising:

a mounting bracket comprising a curved mating surface extending as an arch between a pair of flat mounting feet portions, the mounting bracket configured to hold a PV module coupling device;

a hanger bolt comprising a first threaded portion adapted to engage a roof surface, a second threaded portion adapted to pass through the curved mating surface of the mounting bracket; and

a threaded knob adapted to mate with the second threaded portion of the hanger bolt,

wherein the curved mating surface comprises an elongated slot that the second portion of the hanger bolt passes through.

11. The system of claim 10, wherein the hanger bolt is configured to pass through the mounting bracket at non-transverse angles with respect to the flat mounting feet portions.

12. The system of claim 10, wherein the knob comprises a grip portion for tightening the knob by hand and at least one push nut.

13. The system of claim 10, wherein the threaded knob compresses the curved mating surface against a roof surface when rotational torque is applied to the threaded knob.

14. The system of claim 10, wherein mounting bracket comprises a flat upper portion positioned above the curved mating surface.

15. The system of claim 10, wherein at least one rib connects the first and second arches of the mounting bracket.

16. A photovoltaic (PV) module mounting system comprising:

a mounting bracket comprising an elongated and curved mating surface, the mounting bracket configured to hold a PV module coupling device;

a hanger bolt adapted at a first threaded end to engage a roof surface; and

a threaded knob adapted to mate with a second threaded end of the hanger bolt while pressing against the mating surface, wherein the curved mating surface is shaped to compensate for angular misalignment of the hanger bolt with respect to the mounting bracket,

wherein the mounting bracket comprises a first arch that defines the mating surface, wherein the mounting bracket comprises a second arch disposed above the first arch.

17. The system of claim 16, wherein the hanger bolt can be aligned with the flat mounting feet portions at angles ranging from 80 to 100 degrees.

18. The system of claim 17, wherein the knob comprises an engagement surface configured to at least partially engage with the mating surface when the hanger bolt aligned with the mounting feet portions at any angle in the range.

19. The system of claim 16, wherein the threaded knob is adapted to mate with the hanger bolt by applying rotational torque without requiring tools.

20. The system of claim 16, wherein the hanger bolt includes a washer located between the first threaded end and the second threaded end for limiting a depth that the first threaded portion can achieve in the roof surface.