USOO8938.932B1
`
`(12) United States Patent
`Wentworth et al.
`
`(10) Patent No.:
`(45) Date of Patent:
`
`US 8,938,932 B1
`Jan. 27, 2015
`
`(54) RAIL-LESS ROOF MOUNTING SYSTEM
`(71) Applicant: Quality Product LLC, Walnut Creek,
`CA (US)
`(72) Inventors: Stuart Wentworth, Alamo, CA (US);
`Claudia Wentworth, Alamo, CA (US)
`(73) Assignee: Quality Product LLC, Walnut Creek,
`CA (US)
`Subject to any disclaimer, the term of this
`patent is extended or adjusted under 35
`U.S.C. 154(b) by 0 days.
`(21) Appl. No.: 14/166,633
`
`(*) Notice:
`
`(22) Filed:
`
`Jan. 28, 2014
`
`Related U.S. Application Data
`(60) Provisional application No. 61/916,046, filed on Dec.
`13, 2013.
`
`(2014.01)
`
`(51) Int. Cl.
`E04D 3/8
`(52) U.S. Cl.
`USPC ......................................... 52/747.1; 52/173.3
`(58) Field of Classification Search
`USPC .......... 52/173.3, 710, 747.1, 58, 60: 136/251,
`136/244, 291
`See application file for complete search history.
`
`(56)
`
`References Cited
`
`U.S. PATENT DOCUMENTS
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`(Continued)
`Primary Examiner — Mark Wendell
`(74) Attorney, Agent, or Firm — Temmerman Law Office:
`Mathew J. Temmerman
`
`ABSTRACT
`(57)
`A rail-less roof mounting system for installing photovoltaic
`(PV) modules on a roof structure comprises a base mount
`assembly that engages with a clamp assembly and attaches to
`the roofstructure. The base mount assembly comprises a base
`member having a waterproof means, a block slider, a top
`slider and a covering means. An elevated seal portion of a
`block slider includes a borehole to receive the waterproof
`means. A vertical engaging portion of the block slider is
`attached with a sliding seal member of the top slider. The
`clamp assembly includes a clamp member and a plate mem
`ber and the clamp member is attached with a track of the top
`slider. The clamp member interlocks the PV modules to pro
`vide a corner-to-corner coupling arrangement, which enables
`the connection of PV module corners to adjacent PV module
`corners by sandwiching above and beneath frame members of
`the PV modules.
`
`25 Claims, 12 Drawing Sheets
`
`
`
`146
`
`ECO
`Exhibit 1004 - Page 1
`
`

`

`US 8,938.932 B1
`Page 2
`
`(56)
`
`References Cited
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`52,173.1
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`* cited by examiner
`
`
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`ECO
`Exhibit 1004 - Page 2
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`U.S. Patent
`U.S. Patent
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`Jan. 27, 2015
`Jan. 27, 2015
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`Sheet 1 of 12
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`Exhibit 1004 - Page 3
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`U.S. Patent
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`Jan. 27, 2015
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`Sheet 2 of 12
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`US 8,938,932 B1
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`Sheet 3 of 12
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`Sheet 4 of 12
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`Jan. 27, 2015
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`Jan. 27, 2015
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`Jan. 27, 2015
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`US 8,938,932 B1
`
`1.
`RAIL-LESSROOF MOUNTING SYSTEM
`
`RELATED APPLICATIONS
`
`This application claims priority from the U.S. provisional
`Application with Ser. No. 61/916046 filed on Dec. 13, 2013.
`The disclosure of the provisional application is incorporated
`herein as if set out in full.
`
`BACKGROUND OF THE DISCLOSURE
`
`Technical Field Of The Disclosure
`
`The present embodiment relates in general to mounting
`systems for photovoltaic (PV) modules on roof structures.
`More specifically, the present disclosure relates to a rail-less
`photovoltaic (PV) module mounting system for providing a
`cost-effective means to installa plurality of photovoltaic (PV)
`modules on a roof structure.
`
`DESCRIPTION OF THE RELATED ART
`
`10
`
`15
`
`2
`One of the existing mounting systems describes an inte
`grated module frame and racking system for a Solar panel.
`The system comprises a plurality of Solar modules and a
`plurality of splices for coupling the plurality of Solar modules
`together. The plurality of splices provide a way to make the
`connected modules mechanically rigid both during transport
`to the roof and after mounting for the lifetime of the system;
`provide wiring connections between modules; provide an
`electrical grounding path for the modules; provide a way to
`add modules to the panel; and provide a way to remove or
`change a defective module. Connector Sockets are provided
`on the sides of the PV modules to simplify the electrical
`assembly when the PV modules are connected together with
`splices. However, the frame of the PV module is installed with
`a groove to attach the mounting bracket and a hole to insert the
`splice to connect the PV modules, which results in a labor
`intensive operation. In addition, it requires one mounting
`bracket per PV module and multiple holes in the roof struc
`ture are required for installation, increasing the risk of leaks.
`Another existing mounting system discloses a photovoltaic
`(PV) module framing and coupling system which enables the
`attachment of PV modules to a roof or other mounting surface
`without requiring the use of separate structural Support mem
`bers. The system provides a parallel coupling for securely
`interlocking the outside Surfaces of parallel frame members
`together in a side-to-side arrangement to form an array with
`improved structural load distribution. The coupling member
`may attach to a slot in the frame at Substantially any position
`along the length of the frame thereby enabling the intercon
`nection of adjacent PV modules along both an X and y-axis.
`The system may further provide a rotating portion and lock
`ing portion for coupling to the frame attachment, mounting
`brackets for direct connection to a mounting Surface, ground
`ing teeth for the automatic creation of a reliable two axis
`grounding matrix, and a rapid twist-lock engagement means
`for reliably interlocking and aligning PV modules in the
`array. However, this embodiment includes a side-to-side
`arrangement to forman array and an additional groove/slot is
`formed on the frame to engage coupling member, which
`enables the interconnection of frames of adjacent PV mod
`ules. In addition, the parallel couplings are extended beyond
`corner regions of PV modules.
`Various other mounting systems currently available are
`impossible to retrofit to existing roofs without cutting the
`shingles. The removal of a single PV panel from the PV array
`installed using some of these aforementioned mounting struc
`tures is difficult and can result in re-work thereby increasing
`labor and material costs. Some other systems do not allow for
`the capability to independently remove a single PV panel
`without deconstructing an entire row of PV panels, which
`significantly increases maintenance costs.
`Therefore, there is a need for a rail-less roof mounting
`system that would provide a cost effective and improved
`means for PV module installations. Such a rail-less roof
`mounting system would provide an efficient means of instal
`lation that does not require any additional material or struc
`ture to Support the rail-less roof mounting system. Such a
`rail-less roof mounting system would provide a corner-to
`corner coupling arrangement enabling the bridging of a PV
`module corner directly with adjacent PV module corner. Such
`a needed device would provide reduced shipping and hard
`ware costs, labor and installation time and cost; reduce the
`dead load on the roof structure along with design engineering
`costs; and hard and soft balance of system (BOS) cost. This
`rail-less roof mounting system would provide a single
`grounding lug and a single point of penetration with an
`elevated seal portion for waterproofing the roof structure.
`
`25
`
`30
`
`40
`
`45
`
`With the increased use of photovoltaic (PV) roofing sys
`tems for generating electricity, a demand for mounting hard
`ware, which attaches frames for the purpose of installing the
`PV modules to the roof structure or any other support struc
`ture, has been developed. In recent years, various kinds of
`mounting structures have been used which allow the instal
`lation of PV modules to the roof structures. Mounting struc
`tures come in a variety of sizes and patterns to meet installa
`tion purposes. However, most of the mounting structures
`require increased labortime and cost for installation of the PV
`modules on the roof structures.
`Conventional mounting structures for Supporting PV mod
`35
`ules in frames have considerable drawbacks. For example,
`many mounting structures utilize rails to mount the PV mod
`ules to the roof structure to form a PV array. The use of these
`rails requires additional materials to support the PV modules.
`Because of use of the additional material, these traditional
`mounting structures can result in excess shipping costs. They
`can also limit the PV array layout possibilities and dramati
`cally increase the time for designing, engineering and install
`ing the mounting structures. Existing devices are expensive,
`difficult to use and can require additional manpower to install.
`For example, a typical 5kW PV mounting system designed to
`mount 20 PV panels (15.37% efficient) mounted on a tradi
`tional rail mounting system requires approximately 302 parts
`at a total cost of S0.69/W retail for the mounting structure
`only and weighs over 300 Lbs. Typical installation times for
`a simple 4x5 (4 rows and 5 columns) PV module rail based
`mounting system are approximately 49 man-hours.
`Traditional rail mounting systems require 5 penetrations
`per mount, 4 mounts per PV module, additional grounding
`lugs, and requires specifically engineered PV modules. In
`addition, existing rail mounting systems may have Substan
`dard waterproofing for roofpenetrations, along with complex
`grounding, wire management, and increased labortime on the
`roof structure due to design flaws. Hard and soft balance of
`system (BOS) may include bypass diodes, blocking diodes,
`Solar controller, wiring system, battery and/or inverter etc.
`The hard and soft balance of system (BOS) costs for PV rail
`mounting system are high due to high material costs as well as
`long system engineering and installation times. Also, the
`traditional rail mounting systems require long strings that are
`difficult to breakup, causing difficulty in working around roof
`obstructions (e.g. vents, skylights).
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`Exhibit 1004 - Page 15
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`Such a rail-less roof mounting system would typically be
`designed for implementation on composition shingle roofs,
`tile roofs, metal roofs, low slope roofs, or any roof that would
`benefit from being waterproof. This mounting system would
`also provide simple grounding, wire management, and struc
`tural quality. This system would be simple, inexpensive, and
`lightweight. This system would provide an improved engi
`neering design to accommodate high Snow and wind loads.
`Further, this rail-less roof mounting system would allow an
`installer to easily work around roof obstructions like vents,
`skylights, and other roof protrusions. This system would also
`minimize the number of parts and tools needed to assemble
`and install the PV module. This rail-less roof mounting sys
`tem would provide the ability to increase vertical leveling
`adjustability; to independently remove a single PV module
`without deconstructing an entire row of the PV array; and
`allow for easy mounting height adjustment after PV modules
`are installed. Finally, this rail-less roof mounting system
`would require less manpower to install and rework.
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`SUMMARY OF THE DISCLOSURE
`
`To minimize the limitations found in the prior art, and to
`minimize other limitations that will be apparent upon the
`reading of the specifications, preferred embodiment of the
`present invention provides a rail-less roof mounting system
`for installing a plurality of photovoltaic (PV) modules on a
`roof structure. The rail-less roof mounting system comprises
`a base mount assembly attached to the roof structure. The
`base mount assembly includes a base member having a top
`Surface and a bottom surface, a block slider having an
`elevated seal portion and a vertical engaging portion, and a
`top slider having a top portion and a bottom portion, and a
`clamp assembly having a clamp member and a plate member.
`The top surface of the base member is attached with a
`waterproof means and the bottom surface of the base member
`is engaged with the roof structure. The elevated seal portion,
`having a borehole formed therethrough to receive the water
`proof means, engages with the base member and the roof
`structure, utilizing at least one tightening means that is
`inserted through the borehole. The vertical engaging portion
`has a vertical groove along a surface thereof. The top slider
`having a track with a horizontal groove at the top portion and
`a sliding seal member with a sliding groove and a slot at the
`bottom portion. The sliding seal member slides over the ver
`tical engaging portion through the sliding groove and secures,
`utilizing at least one fastening means that inserts through the
`Vertical groove on the vertical engaging portion. The base
`mount assembly further includes a covering means that is
`adaptable to securely cover the at least one tightening means
`on the elevated seal portion for providing waterproof sealing
`between the base mount assembly and the roof structure.
`The clamp assembly comprises the clamp member that is
`coupled with the plate member. The clamp member includes
`a plurality of apertures on an inner Surface thereof and a
`plurality of holes to receive a plurality of screws and the plate
`member that includes a plurality of slots. The plurality of
`apertures and the plurality of slots are oriented along a com
`mon longitudinal path to receive the at least one securing
`means. The at least one securing means is slid through the
`horizontal groove and inserted through the plurality of slots
`on the plate member and the plurality of apertures on the inner
`surface of the clamp member. Thus, the clamp member, the
`plate member and the top slider are secured to each other
`utilizing the at least one securing means. Thus, the plurality of
`PV modules are interlocked in a way to provide a corner-to
`corner coupling arrangement which enables the connection of
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`US 8,938,932 B1
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`4
`PV module corners to adjacent PV module corners by sand
`wiching above and beneath the frame members of the PV
`modules.
`A first objective of the present invention is to provide a
`corner-to-corner coupling arrangement, enabling the bridg
`ing of a PV module corner directly with adjacent PV module
`COC.
`A second objective of the present invention is to provide an
`efficient means of installation that does not require any addi
`tional material or structure to support the rail-less roof mount
`ing System.
`A third objective of the present invention is to provide a
`cost-effective means for PV modules installation.
`A fourth objective of the present invention is to provide a
`rail-less roof mounting system that reduces dead load on a
`roof structure along with design engineering costs and hard
`and soft balance of system (BOS) costs.
`A fifth objective of the present invention is to provide a
`rail-less roof mounting system that is lightweight and to pro
`vide improved engineering design to accommodate high
`Snow and wind loads.
`A sixth objective of the present invention is to provide a
`rail-less roof mounting system that allows an installer to
`easily work around roof obstructions like vents, skylights,
`and other roof protrusions.
`A seventh objective of the present invention is to provide a
`rail-less roof mounting system that minimize the number of
`parts and tools needed to assemble and install the PV module.
`An eighth objective of the present invention is to provide a
`rail-less roof mounting system that provides the ability to
`increase vertical leveling adjustability.
`A ninth objective of the present invention is to provide a
`rail-less roof mounting system that independently removes a
`single PV module without deconstructing an entire row of the
`PV array.
`Another objective of the present invention is to provide a
`rail-less roof mounting system that allows height adjustment
`of the rail-less roof mounting system after the installation of
`PV modules.
`Yet another object of the present invention is to provide a
`rail-less roof mounting system that has a single grounding lug
`and a single point of penetration with an elevated Seal portion
`for waterproofing the roof structure.
`Still yet another object of the present invention is to provide
`a rail-less roof mounting system that retrofits into existing
`roofs without the need to cut shingles.
`Yet still another object of the present invention is to provide
`a rail-less roof mounting system that eliminates the need to
`transport to the jobsite, configure and cut long heavy rails for
`installation purposes.
`Still yet another object of the present invention is to provide
`a rail-less roof mounting system that can cantilever PV mod
`ules in portrait orientation, landscape orientation or a combi
`nation of both.
`Yet still another object of the present invention is to provide
`a rail-less roof mounting system that employs a plurality of
`wire clips to work in multiple locations to minimize wire
`management issues.
`These and other advantages and features of the present
`invention are described with specificity so as to make the
`present invention understandable to one of ordinary skill in
`the art.
`
`BRIEF DESCRIPTION OF THE DRAWINGS
`
`Elements in the figures have not necessarily been drawn to
`scale in order to enhance their clarity and improve under
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`Exhibit 1004 - Page 16
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`US 8,938,932 B1
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`standing of these various elements and embodiments of the
`invention. Furthermore, elements that are known to be com
`mon and well understood to those in the industry are not
`depicted in order to provide a clear view of the various
`embodiments of the invention, thus the drawings are gener
`alized in form in the interest of clarity and conciseness.
`FIG. 1 illustrates a perspective view of a rail-less roof
`mounting system for installing a plurality of photovoltaic
`(PV) modules on a roof structure in accordance with the
`preferred embodiment of the present invention:
`FIG. 2 illustrates an exploded view of a base mount assem
`bly in accordance with the preferred embodiment of the
`present invention;
`FIG. 3 illustrates an exploded view of a clamp assembly
`associated with the base mount assembly in accordance with
`the preferred embodiment of the present invention;
`FIG. 4 illustrates a first mounting position of the rail-less
`roof mounting system interlocking the plurality of PV mod
`ules to form a corner-to-corner coupling arrangement in
`accordance with the preferred embodiment of the present
`invention;
`FIG. 5 illustrates a second mounting position of the rail
`less roof mounting system interlocking the plurality of PV
`modules to form the corner-to-corner coupling arrangement
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`in accordance with the preferred embodiment of the present
`invention;
`FIG. 6 illustrates the rail-less roof mounting system inter
`locking two PV modules in an arrangement in accordance
`with an alternate configuration of the present invention;
`FIG. 7 illustrates installation of the rail-less roof mounting
`system on the roof structure in accordance with the preferred
`embodiment of the present invention;
`FIG. 8 illustrates the base mount assembly configured to
`adjust mounting height of the rail-less roof mounting system
`in accordance with the preferred embodiment of the present
`invention;
`FIG. 9 illustrates a perspective view of a PV array skirt
`providing a Snap-fit engagement with the rail-less roof
`mounting system in accordance with the preferred embodi
`ment of the present invention;
`FIG. 10 illustrates a profile view of the PV array skirt
`providing the Snap-fit engagement with the rail-less roof
`mounting system shown in FIG. 9;
`FIG.11 illustrates a perspective view of interlocking of two
`PV array skirts in accordance with the preferred embodiment
`of the present invention; and
`FIG. 12 illustrates one embodiment of a clamp assembly in
`accordance with the present invention.
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`DETAILED DESRIPTION OF THE DRAWINGS
`
`In the following discussion that addresses a number of
`embodiments and applications of the present invention, ref
`erence is made to the accompanying drawings that form a part
`hereof, and in which is shown by way of illustration specific
`embodiments in which the invention may be practiced. It is to
`be understood that other embodiments may be utilized and
`changes may be made without departing from the scope of the
`present invention.
`Various inventive features are described below that can
`each be used independently of one another or in combination
`with other features. However, any single inventive feature
`may not address any of the problems discussed above or only
`address one of the problems discussed above. Further, one or
`more of the problems discussed above may not be fully
`addressed by any of the features described below.
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`Turning now to FIG.1, a perspective view of a rail-less roof
`mounting system 100 for installing a plurality of photovoltaic
`(PV) modules 170, 172,174 (See FIG. 4) on a roof structure
`176 (See FIG. 7) in accordance with the preferred embodi
`ment of the present invention is illustrated. The rail-less roof
`mounting system 100 comprises a base mount assembly 102
`that is associated with a clamp assembly 144 to bridge the
`plurality of PV modules 170, 172, 174 and to install the
`plurality of PV modules 170, 172,174 on the roof structure
`176. The base mount assembly 102 attached to the roof struc
`ture 176 comprises a base member 104 having a top surface
`108 and a bottom surface (not shown), a block slider 110
`having an elevated seal portion 112 (See FIG.2) and a vertical
`engaging portion 114 and a top slider 124 having atop portion
`126 and a bottom portion 128.
`The clamp assembly 144 includes a clamp member 146
`that is fixed with a plate member 148. The rail-less roof
`mounting system 100 can be easily disassembled and hence
`provides a compact means of storage when not in use. The
`bottom surface (not shown) of the base member 102 is
`engaged with the roof structure 176. The block slider 110 is
`connected with the base member 104 and with the bottom
`portion 128 of the top slider 124. A track 130 having a hori
`Zontal groove 132 is included at the top portion 126 of the top
`slider 124 and a sliding seal member 134 having a sliding
`groove 136 and a slot 138 are included at the bottom portion
`128 of the top slider 124. The sliding seal member 134 is
`secured to the block slider 110 utilizing at least one fastening
`means 140. The clamp member 146 and the plate member 148
`are attached with the track 130 utilizing at least one securing
`means 150. The clamp member 146 includes a plurality of
`apertures 154 (See FIG. 10) on an inner surface 156 thereof
`and a plurality of holes 157 to receive a plurality of screws
`178. The plate member 148 includes a plurality of slots 152 to
`receive the at least one securing means 150.
`FIG. 2 il