Patent Application
20250141396
The present disclosure relates to devices, assemblies, and methods for mounting at least one object above a roof surface, and specifically to a height adjustment roof mounting system for securely and adjustably mounting one or more objects such as solar panels to a roof, which allows for use with multiple roof types, multiple solar module thicknesses, and flanged and flangeless solar module frames.
Accordingly, provided are devices, assemblies, and methods for securely mounting one or more wires to the underside of a solar module, which allows for use with multiple wire sizes, rail and rail-free solar mounting assemblies, multiple solar module thicknesses, and flanged and flangeless solar module frames.
According to non-limiting embodiments of the disclosure, a roof mount includes a base installable on a roof, an adjustment assembly operatively coupled to the base, the adjustment assembly comprising a partially threaded shaft extending along a first axis substantially perpendicular to the roof, an adjustment nut constrained within the adjustment assembly, and a support nut. A clamp is adjustably connected to the base by the adjustment assembly, and a distance between the clamp and the base is adjustable. The clamp includes a first clamp portion having a central portion, a first support surface and a second support surface. The first support surface includes an angled first portion and a substantially horizontal second portion and the first support surface is configured to support a portion of a first solar panel. The central portion is disposed between the first support surface and the second support surface. The clamp further includes a second clamp portion. The roof mount also includes a fastener connected to the clamp, and the fastener is operable to tighten the second clamp portion to the first clamp portion.
According to other non-limiting embodiments of the disclosure, a roof mount includes a base extending along a second axis, an adjustment assembly operatively coupled to the base, the adjustment assembly comprising a threaded shaft extending along a first axis substantially perpendicular to the second axis, an adjustment nut constrained within the adjustment assembly, and a support nut. A clamp is adjustably connected to the base by the adjustment assembly, and a distance between the clamp and the base is adjustable. The clamp includes a first channel sized to receive and support a first solar panel, the first channel defined between a first top flange and a first bottom flange, the first bottom flange including an angled first portion and a substantially horizontal second portion, the first channel having a first height extending between the first top flange and the first bottom flange, the first height being adjustable. The clamp further includes a second channel sized to receive and support a skirt and sized to receive and support a second solar panel, the second channel defined between a second top flange and a second bottom flange, the second channel having a second height extending between the second top flange and the second bottom flange, the second height being adjustable. The clamp also includes a central portion disposed between the first bottom flange and the second bottom flange, the central portion comprising at least one wall and a horizontal portion defining a slot. The roof mount also includes a first fastener connected to the clamp, the first fastener operable to adjust the first height and second height.
According to other non-limiting embodiments of the disclosure, a roof mounting system includes a roof mount and at least one skirt. The roof mount includes a base installable on a roof, an adjustment assembly operatively coupled to the base, the adjustment assembly comprising a partially threaded shaft extending along a first axis substantially perpendicular to the roof, an adjustment nut constrained within the adjustment assembly, and a support nut. A clamp is adjustably connected to the base by the adjustment assembly, and a distance between the clamp and the base is adjustable. The clamp includes a first clamp portion having a central portion, a first support surface and a second support surface. The first support surface includes an angled first portion and a substantially horizontal second portion and the first support surface is configured to support a portion of a first solar panel. The central portion is disposed between the first support surface and the second support surface. The clamp further includes a second clamp portion. The roof mount also includes a fastener connected to the clamp, and the fastener is operable to tighten the second clamp portion to the first clamp portion. The at least one skirt includes an elongate face, a first protrusion, a first hollow body, a second protrusion, and a second hollow body.
According to other non-limiting embodiments of the disclosure, a roof mount includes a base assembly installable on a roof, the base assembly including a foot, an arm, and a slider. The roof mount further includes a flashing positioned between the foot and the arm, and an adjustment assembly operatively coupled to the slider. The adjustment assembly includes a partially threaded shaft extending along a first axis substantially perpendicular to the roof, an adjustment nut constrained within the adjustment assembly, and a support nut. The roof mount further includes a clamp adjustably connected to the base assembly by the adjustment assembly, and a distance between the clamp and the slider is adjustable. The clamp includes a first clamp portion that includes a central portion, a first support surface and a second support surface. The central portion is disposed between the first support surface and the second support surface. The clamp also includes a second clamp portion, and a first fastener connected to the clamp. The first fastener is operable to tighten the second clamp portion to the first clamp portion.
Further non-limiting illustrative examples of embodiments of the present disclosure will now be set forth in the following numbered clauses.
Clause 1: A roof mount, comprising: a base installable on a roof; an adjustment assembly operatively coupled to the base, the adjustment assembly comprising a partially threaded shaft extending along a first axis substantially perpendicular to the roof, an adjustment nut constrained within the adjustment assembly, and a support nut, a clamp adjustably connected to the base by the adjustment assembly, wherein a distance between the clamp and the base is adjustable, the clamp comprising: a first clamp portion that includes a central portion, a first support surface and a second support surface, the first support surface comprising an angled first portion and a substantially horizontal second portion, the first support surface configured to support a portion of a first solar panel, the central portion disposed between the first support surface and the second support surface; and a second clamp portion; and a fastener connected to the clamp, the fastener operable to tighten the second clamp portion to the first clamp portion.
Clause 2: The roof mount of clause 1, wherein the adjustment assembly is slidable on the base.
Clause 3: The roof mount of clause 1 or 2, further comprising a slider fastener configured to prevent the adjustment assembly from sliding relative to the base.
Clause 4: The roof mount of any of clauses 1-3, wherein the base comprises a seal configured to engage the roof.
Clause 5: The roof mount of any of clauses 1-4, wherein the seal comprises a polymeric material, wherein a bottom surface of the polymeric material comprises a resin layer; and wherein the seal is positioned on a bottom surface of the base.
Clause 6: The roof mount of any of clauses 1-5, wherein an exposed portion of the resin layer is covered by a release sheet.
Clause 7: The roof mount of any of clauses 1-6, wherein the central portion defines an aperture configured to receive the adjustment assembly.
Clause 8: The roof mount of any of clauses 1-7, wherein the adjustment assembly comprises a pedestal operatively coupled to the base, the pedestal receives the partially threaded shaft, and the adjustment nut is constrained within the pedestal.
Clause 9: The roof mount of any of clauses 1-8, wherein the pedestal comprises an upper member, a lower member and two or more side members defining an open space; a first aperture through the upper member; and a second aperture through the lower member, wherein the first aperture and the second aperture are concentric with the first axis and configured to receive the partially threaded shaft.
Clause 10: The roof mount of any of clauses 1-9, wherein the pedestal comprises a first ledge and a second ledge, and wherein the upper member, the first ledge and the second ledge are configured to vertically constrain the adjustment nut within the pedestal.
Clause 11: The roof mount of any of clauses 1-10, wherein the two or more side members and the partially threaded shaft are configured to horizontally constrain the adjustment nut within the pedestal.
Clause 12: The roof mount of any of clauses 1-11, wherein the two or more side members are configured to rotationally constrain the adjustment nut within the pedestal, such that the two or more side members prevent rotation of the adjustment nut.
Clause 13: The roof mount of any of clauses 1-12, wherein the pedestal comprises a first catch extending from the lower member and a first side member of the two or more side members; and a second catch extending from the lower member and a second side member of the two or more side members, wherein the first catch and the second catch are slidably engaged with the base.
Clause 14: The roof mount of any of any of clauses 1-13, wherein the pedestal comprises a pedestal arm extending from the second catch, the pedestal arm comprising an aperture configured to receive a slider fastener, the slider fastener configured to prevent the adjustment assembly from sliding relative to the base.
Clause 15: The roof mount of any of clauses 1-14, wherein the support nut is coupled to the partially threaded shaft below a non-threaded portion of the partially threaded shaft such that the support nut is configured to rotate with the partially threaded shaft, and wherein the support nut is configured to contact and support the central portion such that the clamp is supported above the adjustment assembly.
Clause 16: The roof mount of any of clauses 1-15, wherein a top of the lower clamp portion is contacted by a drive head of the partially threaded shaft such that the partially threaded shaft and the support nut are configured to rotate with respect to the adjustment nut and independently of the lower clamp portion.
Clause 17: The roof mount of any of clauses 1-16, wherein the second support surface is configured to support a portion of a second solar panel.
Clause 18: The roof mount of any of clauses 1-17, wherein the second support surface is configured to support a portion of a skirt.
Clause 19: The roof mount of any of clauses 1-18, further comprising an access defined through the second clamp portion, and a second fastener connected to the clamp, the second fastener operable to tighten the second clamp portion to the first clamp portion.
Clause 20: The roof mount of any of clauses 1-19, wherein the access is defined between the first fastener and the second fastener, and wherein the first fastener and second fastener are positioned at opposite ends of the clamp.
Clause 21: The roof mount of any of clauses 1-20, further comprising a flashing member, the base installable to the roof over the flashing member.
Clause 22: The roof mount of any of clauses 1-21, further comprising a flashing member, the base installable to the roof over the flashing member.
Clause 23: A roof mount, comprising: a base extending along a second axis; an adjustment assembly operatively coupled to the base, the adjustment assembly comprising a threaded shaft extending along a first axis substantially perpendicular to the second axis, an adjustment nut constrained within the adjustment assembly, and a support nut; a clamp adjustably connected to the base by the adjustment assembly, wherein a distance between the clamp and the base is adjustable, the clamp comprising: a first channel sized to receive and support a first solar panel, the first channel defined between a first top flange and a first bottom flange, the first bottom flange including an angled first portion and a substantially horizontal second portion, the first channel having a first height extending between the first top flange and the first bottom flange, the first height being adjustable; and a second channel sized to receive and support a skirt and sized to receive and support a second solar panel, the second channel defined between a second top flange and a second bottom flange, the second channel having a second height extending between the second top flange and the second bottom flange, the second height being adjustable; and a central portion disposed between the first bottom flange and the second bottom flange, the central portion comprising at least one wall and a horizontal portion defining a slot; and a first fastener connected to the clamp, the first fastener operable to adjust the first height and second height.
Clause 24: The roof mount of clause 23, wherein an angled first portion of the first bottom flange and a wall of the at least one wall defines a recess.
Clause 25: The roof mount of clause 23 or 24, wherein the central portion is configured to receive the adjustment assembly.
Clause 26: The roof mount of any of clauses 23-25, wherein the central portion comprises a through hole configured to receive the adjustment assembly and a threaded aperture configured to receive the first fastener.
Clause 27: The roof mount of any of clauses 23-26, wherein the adjustment assembly is slidable on the base.
Clause 28: The roof mount of any of clauses 23-27, further comprising a slider fastener configured to prevent the adjustment assembly from sliding relative to the base.
Clause 29: The roof mount of any of clauses 23-28, wherein the base comprises a seal configured to engage a roof.
Clause 30: The roof mount of any of clauses 23-29, wherein the seal comprises a polymeric material, wherein a bottom surface of the polymeric material comprises a resin layer; and wherein the seal is positioned on a bottom surface of the base.
Clause 31: The roof mount of any of clauses 23-30, wherein an exposed portion of the resin layer is covered by a release sheet.
Clause 32: The roof mount of any of clauses 23-31, wherein the horizontal portion of the central portion defines an aperture configured to receive the adjustment assembly.
Clause 33: The roof mount of any of clauses 23-32, wherein the adjustment assembly comprises a pedestal operatively coupled to the base, the pedestal receives the partially threaded shaft, and the adjustment nut is constrained within the pedestal.
Clause 34: The roof mount of any of clauses 23-33, wherein the pedestal comprises: an upper member, a lower member and two or more side members defining an open space; a first aperture through the upper member; and a second aperture through the lower member, wherein the first aperture and the second aperture are concentric with the first axis and configured to receive the partially threaded shaft.
Clause 35: The roof mount of any of clauses 23-34, wherein the pedestal comprises a first ledge and a second ledge, and wherein the upper member, the first ledge and the second ledge are configured to vertically constrain the adjustment nut within the pedestal.
Clause 36: The roof mount of any of clauses 23-35, wherein the two or more side members and the partially threaded shaft are configured to horizontally constrain the adjustment nut within the pedestal.
Clause 37: The roof mount of any of clauses 23-36, wherein the two or more side members are configured to rotationally constrain the adjustment nut within the pedestal, such that the two or more side members prevent rotation of the adjustment nut.
Clause 38: The roof mount of any of clauses 23-37, wherein the pedestal comprises a first catch extending from the lower member and a first side member of the two or more side members; and a second catch extending from the lower member and a second side member of the two or more side members, wherein the first catch and the second catch each define a groove configured to slidingly couple to a top flange of the base, and wherein the first catch and the second catch are slidably engaged with the base.
Clause 39: The roof mount of any of clauses 23-38, wherein the pedestal comprises a pedestal arm extending from the second catch, the pedestal arm comprising an aperture configured to receive a slider fastener configured to prevent the adjustment assembly from sliding relative to the base.
Clause 40: The roof mount of any of clauses 23-39, wherein the support nut is coupled to the partially threaded shaft below a non-threaded portion of the partially threaded shaft such that the support nut is configured to rotate with the partially threaded shaft, and wherein the support nut is configured to contact and support the central portion such that the clamp is supported above the adjustment assembly.
Clause 41: The roof mount of any of clauses 23-40, wherein a top of the lower clamp portion is contacted by a drive head of the partially threaded shaft such that the partially threaded shaft and the support nut are configured to rotate with respect to the adjustment nut and independently of the lower clamp portion.
Clause 42: The roof mount of any of clauses 23-41, wherein the second channel is configured to receive and support a portion of a second solar panel.
Clause 43: The roof mount of any of clauses 23-42, wherein the second channel is configured to receive and support a portion of a skirt.
Clause 44: The roof mount of any of clauses 23-43, further comprising an access defined through the second clamp portion, and a second fastener connected to the clamp, the second fastener operable to adjust the first height and second height.
Clause 45: The roof mount of any of clauses 23-44, wherein the access is defined between the first fastener and the second fastener, and wherein the first fastener and second fastener are positioned at opposite ends of the clamp.
Clause 46: The roof mount of any of clauses 23-45, further comprising a flashing member, the base installable to a roof over the flashing member.
Clause 47: The roof mount of any of clauses 23-46, further comprising a flashing member, the base installable to a roof over the flashing member.
Clause 48: The roof mount of any of clauses 23-47, wherein the flashing member comprises: a substantially flat portion; a raised portion protruding from the substantially flat portion; and an aperture concentric with the raised portion extending through the flashing member.
Clause 49: The roof mount of any of clauses 23-48, further comprising a gasket configured to engage with the raised portion and the aperture.
Clause 50: The roof mount of any of clauses 23-49, wherein the gasket comprises: a through hole; a cylindrical upper portion extending above the raised portion; and a frustoconical lower portion engaged with an inner surface of the raised portion.
Clause 51: The roof mount of any of clauses 23-50, wherein the base and the flashing member are fastened to the roof with a threaded fastener extending through the base, the gasket, and the raised portion of the flashing member.
Clause 52: The roof mount of any of clauses 23-51, wherein the base comprises a raised central portion and a recess extending from a bottom surface of the base into the raised central portion, the recess configured to receive the raised portion of the flashing member and the gasket.
Clause 53: The roof mount of any of clauses 23-52, wherein the base comprises a base aperture extending through the raised central portion and the recess, the base aperture configured to receive the threaded fastener.
Clause 54: A roof mounting system, comprising: a roof mount comprising: a base installable on a roof; an adjustment assembly operatively coupled to the base, the adjustment assembly comprising a partially threaded shaft extending along a first axis substantially perpendicular to the roof, an adjustment nut constrained within the adjustment assembly, and a support nut, a clamp adjustably connected to the base by the adjustment assembly, wherein a distance between the clamp and the base is adjustable, the clamp comprising: a first clamp portion that includes a central portion, a first support surface and a second support surface, the first support surface comprising an angled first portion and a substantially horizontal second portion, the first support surface configured to support a portion of a first solar panel, the second support surface configured to support a portion of a skirt and configured to support a portion of second solar panel, the central portion disposed between the first support surface and the second support surface; and a second clamp portion; and a fastener connected to the clamp, the fastener operable to tighten the second clamp portion to the first clamp portion; and at least one skirt, wherein each of the at least one skirt comprises: an elongate face; a first protrusion; a first hollow body; a second protrusion; and a second hollow body.
Clause 55: The roof mounting system of clause 54, wherein the first protrusion and the first hollow body of the skirt are received and supported by the second support surface and the second clamp portion, or wherein the first hollow body of the skirt is received and supported by the second support surface and the second clamp portion, or wherein the second protrusion and the second hollow body of the skirt are received and supported by the second support surface and the second clamp portion, or wherein the second hollow body of the skirt is received and supported by the second support surface and the second clamp portion.
Clause 56: The roof mounting system of clause 54 or 55, wherein: the second support surface comprises ridges; a clamping surface of the second clamp portion comprise ridges; a surface of the first protrusion comprises ridges; a first surface, a second surface, and a third surface of the first hollow body each comprise ridges, a surface of the second protrusion comprises ridges; a first surface and a second surface of the second hollow body comprise ridges; the ridges of the clamping surface of the second clamp portion mate with the ridges of either the surface of the first protrusion, the first surface of the first hollow body, the surface of the second protrusion, or the first surface of the second hollow body and the ridges of the second support surface mate with the ridges of either the second surface of the first hollow body or the second surface of the second hollow body when the skirt is received and supported by the second support surface and the second clamp portion.
Clause 57: The roof mounting system of any of clauses 54-56, further comprising at least one corner cover, wherein each of the at least one corner cover comprises: a first portion and second portion connected at a corner joint, a first flange extending from the top of the first portion; a second flange extending from the bottom of the first portion and having a first lower tab; a third flange extending from the top of the second portion; and a fourth flange extending from the bottom of the second portion and having a second lower tab, wherein the at least one corner cover is configured to snap over a corner of the roof mounting system where two skirts meet after the two skirts have been installed.
Clause 58: The roof mounting system of any of clauses 54-57, wherein one or more of the at least one corner covers is an interior corner cover such that the first flange, the second flange, the third flange, and the fourth flange extend perpendicularly away from each other and clip to a first and second skirt of the at least one skirt.
Clause 59: The roof mounting system of any of clauses 54-58, wherein one or more of the at least one corner covers is an exterior corner cover such that the first flange, the second flange, the third flange, and the fourth flange extend perpendicularly toward each other and clip to a first and second skirt of the at least one skirt.
Clause 60: The roof mounting system of any of clauses 54-59, further comprising at least one cap, wherein each of the at least one cap comprises: a pair of upper inserts configured to mate with the first hollow body of a skirt of the at least one skirt; a pair of lower inserts configured to mate with the second hollow body of a skirt of the at least one skirt; and a face connector connecting the pair of upper inserts and the pair of lower inserts.
Clause 61: The roof mounting system of any of clauses 54-60, wherein the at least one cap is received by an end of a first skirt of the at least one skirt such that the first hollow body of the first skirt receives an upper insert of the pair of upper inserts and the second hollow body of the first skirt receives a lower insert of the pair of lower inserts such that the face connecter is coplanar with the elongate face of the first skirt.
Clause 62: The roof mounting system of any of clauses 54-61, wherein the at least one cap is further received by an end of a second skirt of the at least one skirt such that the first hollow body of the second skirt receives an upper insert of the pair of upper inserts and the second hollow body of the second skirt receives a lower insert of the pair of lower inserts, such that the elongate face of the first skirt and the elongate face of the second skirt are held coplanar to each other and to the face connector.
Clause 63: The roof mounting system of any of clauses 54-62, wherein the upper inserts of the pair of upper inserts comprise fingers and the lower inserts of the pair of lower inserts comprise fingers.
Clause 64: A roof mount, comprising: a base assembly installable on a roof, the base assembly comprising a foot, an arm, and a slider; a flashing positioned between the foot and the arm; an adjustment assembly operatively coupled to the slider, the adjustment assembly comprising a partially threaded shaft extending along a first axis substantially perpendicular to the roof, an adjustment nut constrained within the adjustment assembly, and a support nut, a clamp adjustably connected to the base assembly by the adjustment assembly, wherein a distance between the clamp and the slider is adjustable, the clamp comprising: a first clamp portion that includes a central portion, a first support surface and a second support surface, the central portion disposed between the first support surface and the second support surface; and a second clamp portion; and a first fastener connected to the clamp, the first fastener operable to tighten the second clamp portion to the first clamp portion.
Clause 65: The roof mount of clause 64, wherein the arm comprises: a lower horizontal portion including two downwardly extending lips protruding from a bottom surface; a recess extending into the bottom surface; an aperture extending through the bottom surface and the recess between the lips; an upstanding portion; and an upper horizontal portion extending from the upstanding portion, the upper horizontal portion comprising a slot.
Clause 66: The roof mount of clause 64 or 65, wherein the arm comprises an offset Z shape, such that the lower horizontal portion and the upstanding portion define an obtuse angle, the upstanding portion and the upper horizontal portion define an obtuse angle, and a top horizontal surface and a bottom horizontal surface are parallel.
Clause 67: The roof mount of any of clauses 64-66, wherein the foot comprises: a hollow raised portion having opposing flanges extending from the top of the foot in opposite directions; two vertical walls forming the hollow raised portion; a bottom flange extending from a bottom of one of the two vertical walls, the bottom flange having at least one aperture; a recess in the bottom surface of the foot, the recess offset from the at least one aperture; and a first threaded stud extending from the recess through the hollow raised portion and out of the top of the foot.
Clause 68: The roof mount of any of clauses 64-67, wherein the slider comprises: two opposed upstanding slider members extending from a slider base and configured to slidably engage with the adjustment assembly, two base protrusions extending from a bottom surface of the slider base; and a slider aperture extending through the slider base and configured to receive a second threaded stud, wherein the second threaded stud extends through the slider aperture and the slot of the arm to fasten the slider to the arm, and wherein the first threaded stud pierces and extends through the flashing and operatively couples the arm to the foot.
Clause 69: The roof mount of any of clauses 64-68 wherein the flashing comprises a substantially flat portion pierceable by the first threaded stud, the substantially flat portion configured to be supported by the foot and configured to support the arm, and wherein the flashing is monolithically formed.
Clause 70: The roof mount of any of clauses 64-69, wherein the flashing comprises a substantially flat shape and is configured to replace a flat roof tile.
Clause 71: The roof mount of any of clauses 64-70, wherein the flashing comprises an S shape and is configured to replace an S shaped roof tile.
Clause 72: The roof mount of any of clauses 64-71, wherein the flashing comprises a W shape and is configured to replace a W shaped roof tile.
Further details and advantages of the various examples described in detail herein will become clear upon reviewing the following detailed description of the various examples in conjunction with the accompanying drawing figures.
Additional advantages and details are explained in greater detail below with reference to the exemplary embodiments that are illustrated in the accompanying schematic figures, in which:
Corresponding reference characters indicate corresponding parts throughout the several views. The exemplifications set out herein illustrate exemplary embodiments of the disclosure, and such embodiment are not to be construed as limiting the scope of the disclosure in any manner.
It is to be understood that the present disclosure may assume various alternative variations and step sequences, except where expressly specified to the contrary. It is also to be understood that the specific devices and processes illustrated in the attached drawings, and described in the following specification, are simply exemplary and non-limiting embodiments. Hence, specific dimensions and other physical characteristics related to the embodiments disclosed herein are not to be considered as limiting.
For purposes of the description hereinafter, the terms “end,” “upper,” “lower,” “right,” “left,” “vertical,” “horizontal,” “top,” “bottom,” “lateral,” “longitudinal,” and derivatives thereof shall relate to embodiments as they are oriented in the drawing figures. Some non-limiting embodiments may be described herein in connection with thresholds. As used herein, satisfying a threshold may refer to a value being greater than the threshold, more than the threshold, higher than the threshold, greater than or equal to the threshold, less than the threshold, fewer than the threshold, lower than the threshold, less than or equal to the threshold, equal to the threshold, etc.
No aspect, component, element, structure, act, step, function, instruction, and/or the like used herein should be construed as critical or essential unless explicitly described as such. Also, as used herein, the articles “a” and “an” are intended to include one or more items and may be used interchangeably with “one or more” and “at least one.” Furthermore, as used herein, the term “set” is intended to include one or more items (e.g., related items, unrelated items, a combination of related and unrelated items, and/or the like) and may be used interchangeably with “one or more” or “at least one.” As used in the specification and the claims, the singular form of “a,” “an,” and “the” include plural referents, such as unless the context clearly dictates otherwise. Where only one item is intended, the term “one” or similar language is used. Also, as used herein, the terms “comprising,” “including,” “has,” “have,” “having,” variations thereof, and the like are intended to be open-ended terms and are meant to encompass the items listed thereafter and equivalents thereof as well as additional items. Further, the phrase “based on” is intended to mean “based at least partially on” unless explicitly stated otherwise. In addition, reference to an action being “based on” a condition may refer to the action being “in response to” the condition.
Unless specified or limited otherwise, the terms “fastened,” “attached,” “mounted,” “connected,” “supported,” “coupled,” and variations thereof are used broadly and encompass both direct and indirect fastenings, attachments, mountings, connections, supports, and couplings. Further, these terms are not restricted to physical or mechanical connections or couplings unless otherwise specified. As used herein, when referring to a part of a component, the term “member” and/or “members” may be used to refer to features, elements, and/or parts of a whole component that are monolithic, monolithically formed, unitary and/or unitarily formed with the whole component, unless it is explicitly described to the contrary or unless the context clearly dictates otherwise.
Non-limiting embodiments of the present disclosure are generally directed to devices, assemblies, and methods for mounting at least one object above a roof surface, and specifically to a height adjustment roof mounting system for securely and adjustably mounting one or more objects such as solar panels to a roof, which allows for use with multiple roof types, multiple solar module thicknesses, and flanged and flangeless solar module frames.
In some non-limiting embodiments, a roof mount may include a base installable on a roof, an adjustment assembly operatively coupled to the base, the adjustment assembly comprising a partially threaded shaft extending along a first axis substantially perpendicular to the roof, an adjustment nut constrained within the adjustment assembly, and a support nut. A clamp may be adjustably connected to the base by the adjustment assembly, and a distance between the clamp and the base may be adjustable. The clamp may include a first clamp portion having a central portion, a first support surface and a second support surface. The first support surface may include an angled first portion and a substantially horizontal second portion and the first support surface may be configured to support a portion of a first solar panel. The central portion may be disposed between the first support surface and the second support surface. The clamp may further include a second clamp portion. The roof mount may also include a fastener connected to the clamp, and the fastener may be operable to tighten the second clamp portion to the first clamp portion.
In some non-limiting embodiments, the adjustment assembly may be slidable on the base. In some non-limiting embodiments, the roof mount may further include a slider fastener configured to prevent the adjustment assembly from sliding relative to the base.
In some non-limiting embodiments, the base may include a seal configured to engage the roof. In some non-limiting embodiments, the seal may include a polymeric material, a bottom surface of the polymeric material may include a resin layer, and the seal may be positioned on a bottom surface of the base. In some non-limiting embodiments, an exposed portion of the resin layer may be covered by a release sheet.
In some non-limiting embodiments, the central portion may define an aperture configured to receive the adjustment assembly. In some non-limiting embodiments, the adjustment assembly may include a pedestal operatively coupled to the base, the pedestal may receive the partially threaded shaft, and the adjustment nut may be constrained within the pedestal. In some non-limiting embodiments, the pedestal may include an upper member, a lower member and two or more side members defining an open space, a first aperture through the upper member, and a second aperture through the lower member, and the first aperture and the second aperture may be concentric with the first axis and configured to receive the partially threaded shaft.
In some non-limiting embodiments, the pedestal may include a first ledge and a second ledge, and the upper member, the first ledge and the second ledge may be configured to vertically constrain the adjustment nut within the pedestal. In some non-limiting embodiments, the two or more side members and the partially threaded shaft may be configured to horizontally constrain the adjustment nut within the pedestal. In some non-limiting embodiments, the two or more side members may be configured to rotationally constrain the adjustment nut within the pedestal, such that the two or more side members prevent rotation of the adjustment nut.
In some non-limiting embodiments, the pedestal may include a first catch extending from the lower member and a first side member of the two or more side members, and a second catch extending from the lower member and a second side member of the two or more side members, and the first catch and the second catch may be slidably engaged with the base. In some non-limiting embodiments, the pedestal may include a pedestal arm extending from the second catch. In some non-limiting embodiments, the pedestal arm may include an aperture configured to receive a slider fastener, and the slider fastener may be configured to prevent the adjustment assembly from sliding relative to the base.
In some non-limiting embodiments, the support nut may be coupled to the partially threaded shaft below a non-threaded portion of the partially threaded shaft such that the support nut is configured to rotate with the partially threaded shaft and the support nut may be configured to contact and support the central portion such that the clamp is supported above the adjustment assembly. In some non-limiting embodiments, a top of the lower clamp portion may be contacted by a drive head of the partially threaded shaft such that the partially threaded shaft and the support nut may be configured to rotate with respect to the adjustment nut and independently of the lower clamp portion.
In some non-limiting embodiments, the second support surface may be configured to support a portion of a second solar panel. In some non-limiting embodiments, the second support surface may be configured to support a portion of a skirt.
In some non-limiting embodiments, the roof mount may further include an access defined through the second clamp portion, and a second fastener connected to the clamp, and the second fastener may be operable to tighten the second clamp portion to the first clamp portion. In some non-limiting embodiments, the access may be defined between the first fastener and the second fastener, and the first fastener and second fastener may be positioned at opposite ends of the clamp.
In some non-limiting embodiments, the roof mount may further include a flashing member and the base may be installable to the roof over the flashing member.
In this way, embodiments of the present disclosure allow for a height adjustment roof mounting system for securely and adjustably mounting one or more objects such as solar panels to a roof, which allows for use with multiple roof types, multiple solar module thicknesses, and flanged and flangeless solar module frames.
Referring now to
In exemplary embodiments, lower clamp 114 may have a length that is longer than the length of second clamp portion 126. In some non-limiting embodiments, this difference in length may allow access to adjustment assembly 104, and in particular, to partially threaded shaft 106, and more particularly, to drive head 106b of partially threaded shaft 106 without impediment by second clamp portion 126. In this way, adjustment assembly 104 may be adjusted from above second clamp portion 126. This configuration may also reduce material and labor costs.
Roof mount 100 may also include a fastener 128 connected to clamp 112, and fastener 128 may be operable to tighten second clamp portion 126 to first clamp portion 114. This bias may act to hold the first clamp portion 114 and second clamp portion 126 in an open position to receive a skirt or second solar panel before adjusting the distance between the first clamp portion 114 and second clamp portion 126 via fastener 128. In some non-limiting embodiments, fastener 128 may be received within a fastener through hole in second clamp portion 126 and a threaded aperture in first clamp portion 114 to allow tightening of second clamp portion 126 to first clamp portion 114. In some non-limiting embodiments, second clamp portion 126 may further include a counterbore access that allows a head of fastener 128 to be recessed into second clamp portion 126 when fastener 128 is tightened.
As further shown in
In some non-limiting embodiments, roof mount 100 may include spring 145 between first clamp portion 114 and second clamp portion 126, and spring 145 may be configured to bias second clamp portion 126 with respect to first clamp portion 114. In some non-limiting embodiments, second clamp portion 126 may include grounding pins 147 and grounding pins 147 may be configured to pierce a surface (e.g., an anodized surface) of a solar panel, a solar panel frame, and/or a skirt to electrically bond and/or electrically ground the respective components.
In some non-limiting embodiments, base 102 may include seal 132 configured to engage the roof. In some non-limiting embodiments, seal 132 may include polymeric material, and a bottom surface of the polymeric material may include resin layer 134. In some non-limiting embodiments, seal 132 may be positioned on a bottom surface of base 102 (e.g., bottom surface 102a of base 102 shown in
With reference to
As further shown in
With continued reference to
In some non-limiting embodiments, support nut 110 may be coupled to partially threaded shaft 106 below and tightened against non-threaded portion 106a (e.g., non-threaded portion 106a shown in
In some non-limiting embodiments, drive head 106b may sit above the top surface of the first clamp portion 114 and support nut 110 may sit below and support the bottom surface of central portion 116, and partially threaded shaft 106 may be received within mounting aperture 138 which may be an unthreaded clearance aperture. The distance between the bottom of drive head 106b and the top of support nut 110 may be greater than the height of central portion 116 of first clamp portion 114 from the bottom surface of central portion 116 to the top surface of first clamp portion 114. This exemplary configuration may allow partially threaded shaft 106 to rotate freely within first clamp portion 114 and for a drill or other tool to move partially threaded shaft 106 up and down within adjustment nut 108 without rotating clamp 112 and thereby adjusting the height of clamp 112 above base 102 and the mounting surface.
In some non-limiting embodiments, second support surface 120 may be configured to support a portion of a second solar panel (e.g., which may be the same as or similar to solar panel P shown in
In some non-limiting embodiments, roof mount 100 may further include a flashing member (e.g., flashing member 280 shown in
Referring now to
With continued reference to
In exemplary embodiments, roof mount 200 may further include central portion 216 disposed between first bottom flange 214a and the second bottom flange 214b, and central portion 216 may include at least one wall 262 and horizontal portion 264 defining slot 266. In some non-limiting embodiments, roof mount 200 may also include first fastener 228 connected to clamp 212, and first fastener 228 may be operable to adjust first height H1 and second height H2. In some non-limiting embodiments, central portion 216 may be configured to receive adjustment assembly 204. In some non-limiting embodiments, central portion 216 may include through hole 268, and through hole 268 may be configured to receive adjustment assembly 204. In some non-limiting embodiments, horizontal portion 264 of central portion 216 may define mounting aperture 270 configured to receive adjustment assembly 204. In some non-limiting embodiments, central portion 216 may further include threaded aperture 272 configured to receive first fastener 228.
As further shown in
With reference to
As further shown in
With continued reference to
As shown in
In some non-limiting embodiments, drive head 206b may sit above the top surface of horizontal portion 264 and support nut 210 may sit below and support the bottom surface of central portion 216, and partially threaded shaft 206 may be received within mounting aperture 270 and through hole 268 which may be unthreaded clearance apertures. The distance between the bottom of drive head 206b and the top of support nut 210 may be greater than the height of the central portion 216 of first clamp portion 214 from the bottom surface of central portion 216 to the top surface of horizontal portion 264. This exemplary configuration may allow partially threaded shaft 206 to rotate freely within first clamp portion 214 and for a drill or other tool to move partially threaded shaft 206 up and down within adjustment nut 208 without rotating clamp 212 and thereby adjusting the height of clamp 212 above base 202 and the mounting surface.
In some non-limiting embodiments, second channel 212b may be configured to receive and support a portion of a second solar panel (e.g., which may be the same as or similar to solar panel P shown in
With continued reference to
In some non-limiting embodiments, roof mount 200 may further include gasket 288 and gasket 288 may be configured to engage with raised portion 284 and aperture 286. In exemplary embodiments, gasket 288 may include through hole 290, cylindrical upper portion 292 extending above raised portion 284, and frustoconical lower portion 294 engaged with an inner surface of the raised portion.
In some non-limiting embodiments, base 202 and flashing member 280 may be fastened to the roof with threaded fastener 296 extending through base 202, gasket 288, and raised portion 284 of flashing member. In some non-limiting embodiments, base 202 may include a raised central portion 202a and a recess 202b extending from a bottom surface of base 202 into raised central portion 202a. In exemplary embodiments, recess 202b may be configured to receive raised portion 284 of flashing member 280. In some non-limiting embodiments, recess 202b may also be configured to receive gasket 288. In some non-limiting embodiments, bases 202 may include base aperture 202c extending through raised central portion 202a and recess 202b. In exemplary embodiments, base aperture 202c may be configured to receive threaded fastener 296.
Referring now to
In exemplary embodiments, clamp 312 may be longer than the clamp of other non-limiting embodiments such as clamp 112 and/or clamp 212. As shown in
In some non-limiting embodiments, clamp 312 may be a bridge clamp or a coupling, such that first support surface 318 is configured to support a portion of one or more solar panels and second support surface 320 is configured to support a portion of one or more solar panels at the same time. For example, clamp 312 may be used as a bridge clamp as part of a mounting system or solar panel array to bridge the gap between roof mounts such as roof mount 100, 200. In exemplary embodiments, clamp 312 may be provided without the base and/or without adjustment assembly and the associated components thereof. In exemplary embodiments, clamp 312 may support the solar panels coupled thereto and be supported above the roof by the solar panels coupled thereto. As shown in
Referring now to
For example, a roof mount of roof mounting system 1000 may include a base installable on a roof an adjustment assembly operatively coupled to the base. The adjustment assembly may include a partially threaded shaft extending along a first axis substantially perpendicular to the roof, an adjustment nut which may be constrained within the adjustment assembly, and a support nut. A clamp may be adjustably connected to the base by the adjustment assembly, and a distance between the clamp and the base may be adjustable. The clamp may include a first clamp portion having a central portion, a first support surface and a second support surface. The first support surface may include an angled first portion and a substantially horizontal second portion and the first support surface may be configured to support a portion of a first solar panel. The central portion may be disposed between the first support surface and the second support surface. The clamp may further include a second clamp portion. The roof mount may also include a fastener connected to the clamp, and the fastener may be operable to tighten the second clamp portion to the first clamp portion.
With reference to
In some non-limiting embodiments, skirt 400 may be reversible such that it can be installed in two orientations. In a first orientation, first protrusion 402 may be at the top and second protrusion 406 may be at the bottom when skirt 400 is installed in a roof mount. In a second orientation, first protrusion 402 may be at the bottom and second protrusion 406 may be at the top when skirt 400 is installed in a roof mount.
In some non-limiting embodiments, skirt 400, first protrusion 402, first hollow body 404, second protrusion 406, and second hollow body 408 may be sized and configured to be installed in multiple configurations to allow for use with roof mounting system 1000 for installing solar panels with different heights or thicknesses. For example, the distance between surface 402a of first protrusion 402 and second surface 404b of first hollow body 404 may be a first distance D1, the distance between first surface 404a and second surface 404b of first hollow body 404 may be a second distance D2, the distance between second surface 408b of second hollow body 408 and surface 406a of second protrusion 406 may be a third distance D3, and a distance between second surface 408b and first surface 408a of second hollow body 408 may be a fourth distance D4. In some non-limiting embodiments, D1, D2, D3, and D4 may correspond to different solar panel heights or thickness. For example, D1 may be 40 mm and correspond to a solar panel with a 40 mm thickness, D2 may be 32 mm and correspond to a solar panel with a 32 mm thickness, D3 may be 35 mm and correspond to a solar panel with a 35 mm thickness, and D4 may be 30 mm and correspond to a solar panel with a 30 mm thickness.
In some non-limiting embodiments of roof mounting system 1000, first protrusion 402 and first hollow body 404 of skirt 400 may be received and supported by the second support surface and the second clamp portion of the roof mount. In some non-limiting embodiments, first hollow body 404 of skirt 400 may be received and supported by the second support surface and the second clamp portion of the roof mount. In some non-limiting embodiments, second protrusion 406 and second hollow body 408 of skirt 400 may be received and supported by the second support surface and the second clamp portion of the roof mount. In some non-limiting embodiments, second hollow body 408 of skirt 400 may be received and supported by the second support surface and the second clamp portion of the roof mount. Thus, there are various ways in which the second support surface and the second clamp portion of the roof mount may together exert a clamping force on skirt 400 to clamp skirt 400.
In some non-limiting embodiments, the second support surface of the roof mount and a clamping surface of the roof mount may each include ridges. In some non-limiting embodiments, surface 402a of first protrusion 402 may include ridges. In some non-limiting embodiments, first surface 404a, second surface 404b, and third surface 404c of first hollow body 404 may each include ridges. In some non-limiting embodiments, surface 406a of second protrusion 406 may include ridges. In some non-limiting embodiments, first surface 408a and second surface 408b of second hollow body 408 may include ridges. In some non-limiting embodiments, the ridges of the clamping surface of the second clamp portion may mate with the ridges of either surface 402a of first protrusion 402, first surface 404a of first hollow body 404, surface 406a of second protrusion 406, or first surface 408a of second hollow body 408 when skirt 404 is received and supported by the second support surface and the second clamp portion. In some non-limiting embodiments, the ridges of the second support surface may mate with the ridges of either second surface 404b of first hollow body 404 or second surface 408b of second hollow body 408 when skirt 404 is received and supported by the second support surface and the second clamp portion. In some non-limiting embodiments, the ridges of third surface 404c of first hollow body 404 may be identifying ridges that identify which orientation of the skirt is appropriate for use and which surfaces should be clamped in the roof mount to correspond to the thickness of the solar panels being installed. In some non-limiting embodiments, the ridges of third surface 404c of first hollow body 404 may be felt or seen by an installer along the entire length of skirt 400.
In some non-limiting embodiments, roof mounting system 1000 may further include at least one corner cover 500 (e.g., interior corner cover 500a and/or exterior corner cover 500b) as shown in
In some non-limiting embodiments, roof mounting system 1000 may include at least one corner cover 500 where corner cover 500 is an interior corner cover 500a, as shown in
In some non-limiting embodiments, roof mounting system 1000 may include at least one corner cover 500 where corner cover 500 is an exterior corner cover 500b, as shown in
In some non-limiting embodiments, roof mounting system 1000 may include at least one cap 600, as show in
In some non-limiting embodiments, at least one cap 600 may be received by an end of a first skirt 400 such that first hollow body 404 of skirt 400 receives an upper insert of the pair of upper inserts 602a, 602b and second hollow body 408 of first skirt 404 receives a lower insert of the pair of lower inserts 604a, 604b such that face connecter 606 is coplanar with elongate face 401 of first skirt 400. In some exemplary embodiments where cap 600 is only connected to one end of one skirt, cap 600 may be an end cap.
In some non-limiting embodiments, at least one cap 600 may further be received by an end of second skirt 400 such that first hollow body 404 of second skirt 400 receives an upper insert of the pair of upper inserts 602a, 602b and second hollow body 408 of second skirt 404 receives a lower insert of the pair of lower inserts 604a, 604b such that elongate face 401 of first skirt 404 and elongate face of second skirt 404 are held coplanar to each other and to face connecter 606. In some exemplary embodiments where cap 600 is connected to one end of a first skirt and one end of a second skirt, cap 600 may be a skirt splice.
In some non-limiting embodiments, similar to skirt 400, cap 600 may be reversible such that it can be installed in two orientations. In a first orientation, the pair of upper inserts 602a, 602b may be at the top and the pair of lower inserts 604a, 604b may be at the bottom when installed in skirt 400 when skirt 400 is in a first orientation. In a second orientation, the pair of upper inserts 602a, 602b may be at the bottom and the pair of lower inserts 604a, 604b may be at the top when installed in skirt 400 when skirt 400 is in a second orientation. In exemplary embodiments, the pair of upper inserts 602a, 602b and the pair of lower inserts 604a, 604b may include fingers 608 configured to provide additional friction for holding cap 600 in at least one skirt 400. In some non-limiting embodiments, a rear portion of face connector 606 between the pair of upper inserts 602a, 602b may include ridges R that correspond to the ridges of surface 404c of first hollow body 404 of skirt 404. In exemplary embodiments, these ridges of cap 600 may indicate which pair of inserts 602a, 602b, 604a, 604b correspond to which hollow body 404, 408. For example, the upper pair of inserts 602a, 602b may always correspond to first hollow body 404.
Referring now to
In some non-limiting embodiments, as shown in
In some non-limiting embodiments, arm 705 may include an offset Z shape, such that lower horizontal portion 709 and upstanding portion 719 may define an obtuse angle, upstanding portion 719 and upper horizontal portion 721 may define an obtuse angle, and top horizontal surface 721a and bottom horizontal surface 709a may be parallel.
In some non-limiting embodiments, foot 703 may include hollow raised portion 725 having opposing flanges 727a, 727b extending from the top of foot 703 in opposite directions. In some non-limiting embodiments, foot 703 may further include two vertical walls 729a, 729b forming hollow raised portion 725. In some non-limiting embodiments, bottom flange 731 may extend from a bottom of one of two vertical walls 729a, 729b and bottom flange 731 may have at least one aperture 733. Foot 703 may further include first threaded stud 735 extending from recess 715 through hollow raised portion 725 and out of the top of foot 703.
In some non-limiting embodiments, slider 707 may include two opposed upstanding slider members 778 extending from slider base 737. Slider members 778 may be configured to slidably engage with adjustment assembly 704. In some non-limiting embodiments, slider 707 may further include two elongated base protrusions 739a, 739b extending from a bottom surface of slider base 737 and a slider aperture 741 extending through slider base 737 and configured to receive second threaded stud 743. In some non-limiting embodiments, second threaded stud 743 extends through slider aperture 741 and the slot 723 of arm 705 to fasten slider 707 to arm 705. In some non-limiting embodiments, second threaded stud may have a collar for engaging with slot 723. Ise the collar may be sized and configured to engage with slot 723. For example, the collar may be square or second threaded stud 743 may be a carriage bolt. In some non-limiting embodiments, first threaded stud 735 may pierce and extend through flashing 780, and first threaded stud 735 may operatively couple arm 705 to foot 703.
In some non-limiting embodiments, flashing 780 may include a substantially flat portion 781, which may be pierceable by first threaded stud 735. In some non-limiting embodiments, substantially flat portion 781 may be configured to be supported by foot 703 and may be configured to support arm 705. In some non-limiting embodiments, flashing 780 may be monolithically formed.
As shown in
Referring now to
It is to be understood, that while the embodiments of the present disclosure have been described with respect to mounting devices, assemblies, and methods for mounting at least one object above a roof surface, and specifically to a height adjustment roof mounting system for securely and adjustably mounting one or more objects such as solar panels to a roof, which allows for use with multiple roof types, multiple solar module thicknesses, and flanged and flangeless solar module frames, the devices, assemblies, and methods are applicable for, but not limited to, implementation with regard to mounting any number of solar panels and/or any number of other components in a solar array, including but not limited to rails for mounting solar panels, in any conceivable position, and it is considered that there are various other configurations and uses for securely mounting components with the devices, assemblies, and methods of the present disclosure.
While several examples of devices, assemblies, and methods for mounting at least one object above a roof surface are shown in the accompanying figures and described in detail hereinabove, other aspects will be apparent to, and readily made by, those skilled in the art without departing from the scope and spirit of the disclosure. Accordingly, the foregoing description is intended to be illustrative rather than restrictive. The disclosure described hereinabove is defined by the appended claims and all changes to the disclosure that fall within the meaning and range of equivalency of the claims are to be embraced within their scope.
This application claims the benefit of U.S. Provisional Patent Application No. 63/595,263, which was filed Nov. 1, 2023, and U.S. Provisional Patent Application No. 63/673,660, which was filed Jul. 19, 2024, the disclosures of which are hereby incorporated herein by reference in their entirety.
| Number | Date | Country | |
|---|---|---|---|
| 63595263 | Nov 2023 | US | |
| 63673660 | Jul 2024 | US |
