Integrated photovoltaic module mounting system for installation on a sloped surface

Abstract

A mounting system 180 for a solar panel 11 includes a rail 114 having an elongated mounting slot 116 secured to a flexible attaching connector 188 with fasteners and the flexible attaching connector for welding to a geomembrane overlying a slope surface, and a photovoltaic module 11 connected with fasteners to the rail, and optionally a ballast system 145 that includes a ballast tray 146 and ballast 152 coupled with fasteners to the rail.

1 . A solar photovoltaic module mounting system for installation on a sloped surface, comprising:
 a geomembrane sheet for overlaying on a sloped surface;   a pair of elongate flexible strips for disposing in spaced-apart parallel relation to the geomembrane;   a pair of elongate rails, each for securing to a respective one of the flexible strips; and   at least one solar photovoltaic module for attaching to the rails,   whereby the flexible strips being secured to the rails and attached to the geomembrane in spaced-apart parallel relation, support the solar photovoltaic module attached with fasteners to the rails while resisting sliding movement relative to the geomembrane and resisting wind uplift.   
     
     
         2 . The solar photovoltaic module mounting system as recited in  claim 1 , wherein the rail comprises a U-channel having a base and opposing side walls extending in a first direction therefrom, each side wall with a free distal end and a lip projecting towards the lip of the opposing distal end. 
     
     
         3 . The solar photovoltaic module mounting system as recited in  claim 2 , further comprising a plurality of fasteners for securing the photovoltaic module to the rails, each fastener comprising a plate having a threaded shaft extending therefrom for receiving the plate between the opposing side walls and the shaft for rotating to drive opposing ends of the plate into contact with the lips of the side walls, the threaded shaft for extending through an opening in a bracket of the solar photovoltaic module and being secured with a nut thereon. 
     
     
         4 . The solar photovoltaic module mounting system as recited in  claim 3 , wherein said plate has a selected width smaller than the width of a channel defined by the opposing side walls and a length larger than the width of said channel. 
     
     
         5 . The solar photovoltaic module mounting system as recited in  claim 1 , further comprising at least one ballast tray having opposing ends for attaching to the opposing rails and a tray surface for supporting a ballast thereon, the ballast tray attached to the opposing rails prior to attaching the solar photovoltaic module to the rails in overlying relation. 
     
     
         6 . The solar photovoltaic module mounting system as recited in  claim 1 , wherein the geomembrane and the flexible strips are made of a synthetic material for heat welding together for secure attaching of the flexible strips to the geomembrane. 
     
     
         7 . The solar photovoltaic module mounting system as recited in  claim 5 , wherein the geomembrane includes a light-reflective component. 
     
     
         8 . The solar photovoltaic module mounting system as recited in  claim 1 , wherein the sloped surface comprises a protected membrane roof; and further comprising an adhesive for securely attaching the geomembrane to the sloped surface. 
     
     
         9 . The solar photovoltaic module mounting system as recited in  claim 1 , further comprising a spacer for attaching between the rail and the solar photovoltaic module to define an air flow space between a bottom surface of the solar photovoltaic module and the geomembrane, whereby air flow therethrough reduces heat build-up in the solar photovoltaic module. 
     
     
         10 . The solar photovoltaic module mounting system as recited in  claim 9 , wherein the spacer comprises a U-shaped channel having a base with at least one opening for receiving a fastener for securing the spacer to the rail, and opposing side walls extending in a first direction therefrom, each side wall with a free distal end and a lip projecting towards the lip of the opposing distal end. 
     
     
         11 . A method of installing a solar photovoltaic module on a sloped surface, comprising the step of:
 (a) providing a geomembrane sheet that overlays a sloped surface;   (b) attaching a pair of elongate flexible strips in spaced-apart parallel relation to the geomembrane, the flexible strip each including an elongate rail secured thereto; and   (c) attaching at least one solar photovoltaic module to the rails,   whereby the flexible strips being secured to the rails and attached to the geomembrane in spaced-apart parallel relation, support the solar photovoltaic module attached with fasteners to the rails while resisting sliding movement relative to the geomembrane and resisting wind uplift.   
     
     
         12 . The method as recited in  claim 11 , wherein the rail comprises a U-channel having a base and opposing side walls extending in a first direction therefrom, each side wall with a free distal end and a lip projecting towards the lip of the opposing distal end. 
     
     
         13 . The method as recited in  claim 11 , further comprising the step of securing the photovoltaic module to the rails with a plurality of fasteners. 
     
     
         14 . The method as recited in  claim 13 , wherein securing comprises receiving a plate between the opposing side walls and being rotated the opposing ends of the plate contact the lips of the side walls, and a threaded shaft extending from the plate receiving a nut. 
     
     
         15 . The method as recited in  claim 11 , forming the geomembrane and the flexible strips of a synthetic material for heat welding together for secure attaching of the flexible strips to the geomembrane. 
     
     
         16 . The method as recited in  claim 11 , further comprising the step of providing the geomembrane with a light-reflective component. 
     
     
         17 . The method as recited in  claim 11 , further comprising the step of adhering the geomembrane with an adhesive to a roof surface. 
     
     
         18 . The method as recited in  claim 11 , further comprising the step of positioning a spacer between the rail and the solar photovoltaic module to define an air flow space between a bottom surface of the solar photovoltaic module and the geomembrane, whereby air flow therethrough reduces heat build-up in the solar photovoltaic module.