PV Roof Anchor Sealant Injection for Leak-Safe Mounting
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Solution Overview
Problem
Existing photovoltaic mounting systems face challenges in providing reliable and controlled sealing of roof penetrations, leading to potential water leaks and increased costs due to the use of flashings and separate sealants, which can be messy and prone to installer errors.
Innovation Solution
The development of anchors with a sealant injection system that includes a collapsible sealant reservoir and a support surface to direct sealant flow around mechanical fasteners, ensuring uniform sealing and chemical flashing, integrated into a photovoltaic mounting system for secure and efficient sealing of roof penetrations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional flashings and separate sealant application are used, then sealing coverage is provided, but the process is messy and prone to installer errors
Solution Approach 1:
The patent combines the flashing and sealant application into a single integrated component. The sealant is pre-applied to the flashing in a controlled manufacturing setting, eliminating the need for installers to separately apply sealant on-site. This integration ensures proper sealing without the mess and errors associated with manual sealant application.
Solution Approach 2:
The sealant is applied to the flashing during manufacturing before installation. This preliminary action ensures that the flashing arrives at the installation site already prepared with the correct amount and placement of sealant, eliminating on-site sealant application steps and ensuring consistent quality.
2Reliability
If flashings are used to cover penetrations, then sealing is provided, but costs increase due to more metal material
Solution Approach 1:
Instead of using large flashings that cover extensive areas, the invention applies sealant only in the specific locations where penetrations occur. This localized approach provides the necessary sealing functionality while using significantly less metal material, reducing both material costs and waste.
3Strength
If lag bolts are driven through the roof, then secure anchoring is achieved, but water leak points are created
Solution Approach 1:
The invention merges the anchoring function (lag bolt) with the sealing function (flashings with pre-applied sealant) into a single integrated assembly. The lag bolt is pre-installed through the flashing with sealant already in place, ensuring that as the bolt secures the roof, the sealant simultaneously seals around the penetration point, preventing water leaks.
4Adaptability or versatility
If multiple products are stocked for sealing, then sealing options are available, but inventory complexity increases
Solution Approach 1:
The flashing is designed as a universal component that performs multiple functions: it provides structural support, creates a weather barrier, and includes pre-applied sealant for sealing penetrations. This multi-functional design eliminates the need to stock separate sealant tubes and flashings, simplifying inventory while maintaining versatility.
Data Source
AI summary
Photovoltaic mounting systems having sealant injection system are provided herein. Such sealant injection systems provide directional control and containment of sealant flow providing improved sealing of roof penetrations of a mounted roof anchor. Such systems can include an anchor having a base and mechanical fastener and a sealant injection package, which includes a collapsible sealant injection reservoir and is adapted to provide directionally controlled release and containment of sealant upon tightening of the mechanical fastener into the roof surface. Such systems can include a sealant carrier that fits into an underside cavity of the anchor base and isolates the sealant injection package from anchoring load paths. The carrier can also define a flow path and sealant area in an underside recessed portion defining a cavity between the carrier and roof surface to provide a more uniform consistent sealant flow to form a chemical flashing about any roof penetration.