Photovoltaic mounting system for tiled roofs

• US 9,806,668 B2
• Filed: 09/15/2015
• Issued: 10/31/2017
• Est. Priority Date: 09/23/2014
• Status: Active Grant

• Current Assignee: Tesla Inc.
• Original Assignee: SolarCity Corporation (Tesla Inc.)
• Inventors: Johansen, Emil, Seery, Martin
• Primary Examiner(s): Quast, Elizabeth A
• Application Number:
  US14/855,273
• Publication Number:
  US 20160087576A1
• Time in Patent Office: 777 Days
• CPC Class Codes: E04D 1/36 Devices for sealing the spaces or joints between roof-covering elements sealing joints not restricted to roof-covering elements E04B1/68; channels at the intersection of roof surfaces E04D13/0445
• CPC Class Codes: E04D 13/147 specially adapted for inclined roofs trays for cavity walls E04B1/70
• CPC Class Codes: F24S 25/30 using elongate rigid mounting elements extending substantially along the supporting surface, e.g. for covering buildings with solar heat collectors extending in directions away from the supporting surface F24S25/10; peripheral frames for modules F24S25/20
• CPC Class Codes: F24S 25/61 for fixing to the ground or to building structures
• CPC Class Codes: F24S 25/613 in the form of bent strips or assemblies of strips; Hook-like connectors; Connectors to be mounted between building-covering elements
• CPC Class Codes: F24S 25/632 Side connectors; Base connectors
• CPC Class Codes: F24S 25/636 clamping by screw-threaded elements
• CPC Class Codes: H02S 20/22 specially adapted for buildings
• CPC Class Codes: H02S 20/23 specially adapted for roof structures
• CPC Class Codes: H02S 20/25 Roof tile elements
• 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 mounting system for tile roofs is disclosed. In one embodiment, mounting bracket is attached to a roof deck and passes through a flashing support and flexible flashing that mimics the contour of the adjacent roof tiles. In other embodiments, a tile hook passes through partial or full tile replacement flashing. A plug or other structure blocks the space around the tile hook preventing the ingress of pests and debris under the flashing and surrounding tiles. Additional photovoltaic module mounting hardware, including sections of rails and frame mounts are attached either the mounting bracket or tile hook.

Claims

1. A system for mounting photovoltaic modules on a tile roof comprising:

a mounting bracket, including a base portion with at least one through-hole formed therein for attaching to a roof deck and a projecting portion configured for attaching one or more photovoltaic module mounting components;

a flashing support member having a flat roof-facing surface, and a curved array-facing surface, wherein the curved array-facing surface at least partially mimics a contour of a roof tile and includes a plurality of slots formed therein to allow the projecting portion of the mounting bracket to pass through at different positions; and

a flashing portion having an elastic opening in a surface thereof, said opening adapted to permit the mounting bracket to pass through, wherein the flashing portion is comprised of a material capable of conforming to contours of the flashing support member and four surrounding tiles.

2. The system of claim 1, further comprising a photovoltaic module connector coupled to the projecting portion of the mounting bracket.

3. The system of claim 2, wherein the photovoltaic module connector comprises rock-it connector.

4. The system of claim 2, wherein the photovoltaic module connector comprises a clamping connector.

5. The system of claim 2, further comprising an adapter and arm member coupling the photovoltaic module connector to the projecting portion of the mounting bracket.

6. The system of claim 2, further comprising a rail member and a rail bracket coupling the photovoltaic module connector to the projecting portion of the mounting bracket.

7. A system for mounting photovoltaic modules comprising:

a mounting bracket, including a base portion with at least one through-hole formed therein for attaching to a roof deck and a projecting portion configured for attaching one or more photovoltaic module mounting components;

a flashing support member pre-formed to partially mimic a contour of a roof tile and including a plurality of slots formed therein to allow the projecting portion of the mounting bracket to pass through at different locations;

a flashing portion having at least one opening formed in a surface thereof, said opening adapted to permit the projecting portion to pass through; and

a flashing boot having a flexible aperture formed therein, and adapted to fit over the projecting portion thereby creating a seal between the boot and the projecting portion and between the boot and the flashing portion.

8. The system of claim 7, further comprising a photovoltaic module connector coupled to the projecting portion of the mounting bracket.

9. The system of claim 8, wherein the photovoltaic module connector comprises rock-it connector.

10. The system of claim 8, wherein the photovoltaic module connector comprises a clamping connector.

11. The system of claim 8, further comprising an arm member coupling the photovoltaic module support to the projecting portion of the mounting bracket.

12. The system of claim 8, further comprising a rail member coupling the photovoltaic module support to the projecting portion of the mounting bracket.

13. The system of claim 7, wherein the flashing portion is pre-formed to match a contour of the flashing support and adjacent roof tiles.

14. The system of claim 7, wherein the flashing portion is comprised of a material capable of conforming to contours of the flashing support member and four surrounding tiles.