Rail-less roof mounting system

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 roof structure. 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 member and the clamp member is attached with a track of the top slider. The clamp member interlocks the PV modules to provide 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.

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 install a plurality of photovoltaic (PV) modules on a roof structure.

DESCRIPTION OF THE RELATED ART

With the increased use of photovoltaic (PV) roofing systems for generating electricity, a demand for mounting hardware, which attaches frames for the purpose of installing the PV modules to the roof structure or any other support structure, has been developed. In recent years, various kinds of mounting structures have been used which allow the installation of PV modules to the roof structures. Mounting structures come in a variety of sizes and patterns to meet installation purposes. However, most of the mounting structures require increased labor time and cost for installation of the PV modules on the roof structures.

Conventional mounting structures for supporting PV modules in frames have considerable drawbacks. For example, many mounting structures utilize rails to mount the PV modules 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 dramatically increase the time for designing, engineering and installing the mounting structures. Existing devices are expensive, difficult to use and can require additional manpower to install. For example, a typical 5 kW PV mounting system designed to mount 20 PV panels (15.37% efficient) mounted on a traditional rail mounting system requires approximately 302 parts at a total cost of $0.69/W retail for the mounting structure only and weighs over 300 Lbs. Typical installation times for a simple 4×5 (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 substandard waterproofing for roof penetrations, along with complex grounding, wire management, and increased labor time 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 break up, causing difficulty in working around roof obstructions (e.g. vents, skylights).

One of the existing mounting systems describes an integrated 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 structure 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 members. 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 interconnection of adjacent PV modules along both an x and y-axis. The system may further provide a rotating portion and locking portion for coupling to the frame attachment, mounting brackets for direct connection to a mounting surface, grounding 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 form an array and an additional groove/slot is formed on the frame to engage coupling member, which enables the interconnection of frames of adjacent PV modules. 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 structures 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 installation that does not require any additional material or structure 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 hardware 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. 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 structural quality. This system would be simple, inexpensive, and lightweight. This system would provide an improved engineering 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 system 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.

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 waterproof 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 vertical 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 common 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 PV module corners to adjacent PV module corners by sandwiching 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 bridging of a PV module corner directly with adjacent PV module corner.

A second objective of the present invention is to provide an efficient means of installation that does not require any additional material or structure to support the rail-less roof mounting 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 provide 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 modules in portrait orientation, landscape orientation or a combination 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.

DETAILED DESRIPTION OF THE DRAWINGS

In the following discussion that addresses a number of embodiments and applications of the present invention, reference 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.

Turning now toFIG. 1, a perspective view of a rail-less roof mounting system100for installing a plurality of photovoltaic (PV) modules170,172,174(SeeFIG. 4) on a roof structure176(SeeFIG. 7) in accordance with the preferred embodiment of the present invention is illustrated. The rail-less roof mounting system100comprises a base mount assembly102that is associated with a clamp assembly144to bridge the plurality of PV modules170,172,174and to install the plurality of PV modules170,172,174on the roof structure176. The base mount assembly102attached to the roof structure176comprises a base member104having a top surface108and a bottom surface (not shown), a block slider110having an elevated seal portion112(SeeFIG. 2) and a vertical engaging portion114and a top slider124having a top portion126and a bottom portion128.

The clamp assembly144includes a clamp member146that is fixed with a plate member148. The rail-less roof mounting system100can be easily disassembled and hence provides a compact means of storage when not in use. The bottom surface (not shown) of the base member102is engaged with the roof structure176. The block slider110is connected with the base member104and with the bottom portion128of the top slider124. A track130having a horizontal groove132is included at the top portion126of the top slider124and a sliding seal member134having a sliding groove136and a slot138are included at the bottom portion128of the top slider124. The sliding seal member134is secured to the block slider110utilizing at least one fastening means140. The clamp member146and the plate member148are attached with the track130utilizing at least one securing means150. The clamp member146includes a plurality of apertures154(SeeFIG. 10) on an inner surface156thereof and a plurality of holes157to receive a plurality of screws178. The plate member148includes a plurality of slots152to receive the at least one securing means150.

FIG. 2illustrates an exploded view of the base mount assembly102in accordance with the preferred embodiment of the present invention. A waterproof means106is attached on the top surface108of the base member104. In the preferred embodiment, the base member104is made from an aluminum flashing. The bottom surface (not shown) of the base member104is engaged with the roof structure176. The elevated seal portion112, having a borehole116formed therethrough to receive the waterproof means106, engages with the base member104and the roof structure176, utilizing at least one tightening means118that is inserted through the borehole116and the waterproof means106. Then, the at least one tightening means118comes from the borehole116and the waterproof means106is drilled into the roof structure176. The base mount assembly102includes a covering means142that is adaptable to securely cover the at least one tightening means118on the elevated seal portion112for providing waterproof sealing between the base mount assembly102and the roof structure176.

The at least one tightening means118is of the type typically known in construction/installation and may comprise a structural screw. Specifically, the at least one tightening means118is a T-30/hex washer head lag screw. A sealing washer158is utilized for fitting on the at least one tightening means118and adapted to seal the borehole116in the elevated seal portion112, through which the at least one tightening means118is fitted, so as to prevent seepage of water. Preferably, the sealing washer158is an annular disc, which is deformable to create a tight seal. In one embodiment, the sealing washer158comprises a disk of rigid material such as steel, with a section or outer layer of deformable material that may be selected from a group consisting of: fluorinated silicone, polyurethane and rubber. Additionally, the sealing washer158, which is most likely to experience wear, is a simple, inexpensive part that can be replaced individually, as needed.

The vertical engaging portion114of the block slider110has a vertical groove120along the surface122thereof. The sliding seal member134of the top slider124slides over the vertical engaging portion114through the sliding groove136on the top slider124and secures to the block slider110, utilizing the at least one fastening means140that is inserted through the vertical groove120on the vertical engaging portion114and the slot138on the sliding seal member134. Preferably, the at least one fastening means140can be in the form of, for example, a cap screw or similar structures. The at least one fastening means140is securely tightened utilizing a lock nut162. Typically, the lock nut is a serrated flange hex nut. The base mount assembly102further includes a plurality of wire clips163for holding/retaining one or more wires (not shown) from/for each PV module170,172,174that is mounted to a building surface by the clamp member146.

FIG. 3illustrates an exploded view of the clamp assembly144associated with the base mount assembly102in accordance with the preferred embodiment of the present invention. The clamp assembly144comprises the clamp member146that is coupled with the plate member148. The clamp member146includes a plurality of apertures154(SeeFIG. 10) on an inner surface156thereof and a plurality of holes157to receive a plurality of screws178, and the plate member148includes a plurality of slots152. The plurality of apertures154and the plurality of slots152are oriented along a common longitudinal path to receive the at least one securing means150.

The clamp assembly144is assembled with the base mount assembly102when in use. The at least one securing means150is slid through the horizontal groove132and inserted through the plurality of slots152on the plate member148and the plurality of apertures154on the inner surface156of the clamp member146. Thus, the clamp member146, the plate member148and the top slider124are secured to each other utilizing the at least one securing means150. The at least one securing means150may comprise a cap screw. Preferably, the at least one securing means150is a stainless steel 5/16 “∅×2” grade 18/8 machine bolt. While securing the clamp assembly144with the base mount assembly102, an engaging nut160and a plurality of retainer rings161are utilized with the at least one securing means150to provide a tight seal. Preferably, the plurality of retainer rings161is made of plastic and the engaging nut160is a hex nut. It is noted that the engaging nut160utilized with the at least one securing means150replaces the conventional brake and provides a tight, secure attachment between the clamp assembly144and the base mount assembly102. The least one securing means150is securely tightened utilizing the lock nut162. Specifically, the lock nut162is a serrated flange hex nut.

The clamp member146replaces the conventional brake and eliminates edge bridge/mid edge conflict. This clamp assembly144works both on top of the base mount assembly102as well as independently. Such clamp assembly144is adjustable to fit “off-the-shelf” available PV modules. Moreover, the clamp assembly144is adjustable to mount most standard size PV modules. Furthermore, the clamp assembly144can fit all types of framed and frameless PV modules.

FIG. 4illustrates a first mounting position of the rail-less roof mounting system100interlocking the plurality of PV modules170,172,174to form a corner-to-corner coupling arrangement in accordance with the preferred embodiment of the present invention. The clamp member146interconnects the frame member164of the PV module170to the frame member166of the adjacent PV module172. The clamp member146is attached to the frame members164,166,168of the plurality of PV modules170,172,174by inserting a plurality of screws178into the plurality of holes157at a middle of a formed PV array. In the first mounting position, the clamp assembly144is coupled with the base mount assembly102, utilizing one of the securing means150that is inserted through one of the apertures154in the inner surface156of the clamp member146and one of the slots152on the plate member148.

FIG. 5illustrates a second mounting position of the rail-less roof mounting system100interlocking the plurality of PV modules170,172,174to form the corner-to-corner coupling arrangement in accordance with the preferred embodiment of the present invention. The clamp member146interconnects the frame member164of the PV module170to the frame member166of the adjacent PV module172. In the second mounting position, the clamp assembly144is coupled with the base mount assembly102utilizing another securing means150that is inserted through another aperture154in the inner surface156of the clamp member146and another slot152on the plate member148.

For instance, the clamp member146interlocks corners of the frame members164,166,168of the plurality of PV modules170,172,174to form a corner-to-corner coupling arrangement as illustrated inFIGS. 4 and 5. Although the rail-less roof mounting system100is shown inFIGS. 4 and 5holding three PV modules170,172,174, it is noted that the at least one rail-less roof mounting system100can bridge four PV modules at the corners in any row and column configuration. Thus, the plurality of PV modules170,172,174are interlocked in a way to provide the corner-to-corner coupling arrangement which enables the connection of PV module corners to adjacent PV module corners by sandwiching above and beneath the frame members164,166,168of the plurality of PV modules170,172,174. Moreover, the clamp member146interlocks top and bottom surfaces of the frame members164,166,168of the plurality of PV modules170,172,174as shown inFIGS. 4 and 5.

In the preferred embodiment, the plurality of PV modules170,172,174provided is aluminum framed PV modules. However, while the present invention will be described for use with a framed PV module, the present invention is not so limited. Thus, it is within the scope of the present invention that rigid frameless PV modules, i.e. PV modules utilizing glass modules, may also be utilized to practice the present invention. In one embodiment, the corner-to corner coupling arrangement provides connection with other mounting and/or racking components and does not provide attachment or connection with any portion of the roof structure176such as waterproofing layers, structural rooftop layers or any/all cosmetic layers.

FIG. 6illustrates the rail-less roof mounting system100interlocking two PV modules192,194in accordance with an alternate configuration of the present invention. In this configuration, the rail-less roof mounting system100interlocks top and bottom surfaces of frame members of two adjacent PV modules192,194at an end of a formed PV array.

FIG. 7illustrates installation of the rail-less roof mounting system100on the roof structure176in accordance with the preferred embodiment of the present invention. The roof structure176serves as a mounting surface for the base mount assembly102. The base member104is placed on the roof structure176and the at least one tightening means118is inserted through the borehole116, the waterproof means106and a roof rafter180that is positioned just beneath a roofing material182and a roofing sheathing184. The illustrative installation provides a single point of penetration with the elevated seal portion112for providing waterproofing. A minimum embedment depth of 2½ inches is preferred. Typically, the at least one tightening means118is a GRK RSS rugged structural screw made of specially hardened steel to provide with high tensile, torque and shear strength. For example, the screw has a 5/16 inch nominal diameter underneath the sealing washer158, a minimum of torque screw to 13 ft-lb and may be made of hardened steel preferably with an all weather coating such as Climatek™ coating. Furthermore, the roof structure176can include pre-stamped and/or pre-drilled pilot holes formed therein through which the at least one tightening means118can be inserted. For example, the pilot holes have a diameter of about ⅛ of an inch. More profitably, the rail-less roof mounting system100is easily and quickly installed with minimal tools, such as a ½ inch open-end box wrench and a ½ inch socket.

A method for installing a plurality of photovoltaic (PV) modules170,172,174on a roof structure176includes the following steps. Firstly, a rail-less roof mounting system100is provided for mounting the plurality of PV modules170,172,174. The base member104is placed on the roof structure176and the block slider110is positioned above the base member104by inserting the waterproof means106through the borehole116on the elevated seal portion112. The at least one tightening means118is inserted through the borehole116and the waterproof means106to secure the block slider110and the base member104with the roof structure176. The sliding seal member134is slid over the vertical engaging portion114through the sliding groove136on the top slider124. The at least one fastening means140is inserted through the vertical groove120on the vertical engaging portion114and the slot138on the top slider124to attach the top slider124to the block slider110. The at least one fastening means140is tightened utilizing the lock nut162. The at least one securing means150is slid through the horizontal groove132and inserted through the plurality of slots152on the plate member148and a plurality of apertures154on clamp member146to attach the clamp member146and the plate member148with the track130of the top slider124. The at least one securing means150is tightened utilizing the lock nut162.

Then, the clamp member146interconnects the frame member164of the PV module170to the frame member166of the adjacent PV module172to provide a corner-to-corner coupling arrangement. Finally, the clamp member146is attached with the frame member164of the PV module170by inserting a plurality of screws178into a plurality of holes157on the clamp member146. Thus, the corner-to-corner coupling arrangement enables the connection of PV module corners to adjacent PV module corners by sandwiching above and beneath the frame members164,166,168of the plurality of PV modules170,172,174.

FIG. 8illustrates the base mount assembly102configured to adjust the mounting height of the rail-less roof mounting system100in accordance with the preferred embodiment of the present invention. The height of mounting of the rail-less roof mounting system100is adjusted by adjusting the position of the top slider124along the vertical engaging portion114of the block slider110. The top slider124can be moved along the vertical engaging portion114and can be secured at desired position or height by tightening the at least one fastening means140through the vertical groove120on the vertical engaging portion114and the slot138on the sliding seal member134.

FIGS. 9 and 10illustrate perspective and profile views of a PV array skirt186providing a snap-fit engagement with the rail-less roof mounting system100in accordance with the preferred embodiment of the present invention. A PV array skirt186is installed on an edge of a PV array. The PV array skirt186may provide improved aesthetics, safety and structural performance. The PV array skirt186may partially or fully obscure air gap and mounting hardware located beneath the PV array. The PV array skirt186may allow for the snap-fit engagement of the PV array skirt186to the rail-less roof mounting system100. The rail-less roof mounting system100may also allow for the snap-fit engagement with the plurality of PV modules170,172,174. The snap-fit engagement between the PV array skirt186and the rail-less roof mounting system100is achieved by inserting an extrusion188of the PV array skirt186along a grooved edge147of the plate member148. Thus, the grooved edge147provides a seat for the extrusion188of the PV array skirt186to provide the snap-fit engagement. The snap-fit engagement provides a longer landing ability to the plate member148and an ability to easily clean out debris from under the PV array skirt186.

FIG. 11illustrates a perspective view of interlocking of two PV array skirts186in accordance with the preferred embodiment of the present invention. The two PV array skirts186are placed end-to-end and ready to be interlocked together with a plurality of skirt clips190. The plurality of skirt clips190is adaptable to prevent the PV array skirt186from sagging. The PV array skirt186may be manufactured from bent metal and may snap onto the rail-less roof mounting system100via the grooved edge147of the plate member148. The rail-less roof mounting system100allows for vertical height adjustment therefore allowing for adjustment of height of the PV array skirt186above the roof structure176thus preventing the debris from entering the underlying air gap. A gap provided between the PV array skirt186and the frame member164may be sized in order to enable adequate room for installing the plurality of wire clips163or any other mounting structures.

The embodiments discussed above allow for portrait orientation, landscape orientation or a combination of both. In a portrait orientation, the PV array having each of the plurality of PV modules170,172,174oriented, with the longest axis of the plurality of PV modules170,172,174extend in a forward-rearward direction, which is typically the south-north direction. The plurality of PV modules170,172,174have long edges with length running in cross-slope direction. It is noted, however, that the plurality of PV modules170,172,174can alternatively be oriented in a landscape orientation, that is, with the longest axis of the plurality of PV modules170,172,174extending in a lateral or side-to-side direction which is typically the east-west direction. Thus, the above-disclosed rail-less roof mounting system100can be used for gable roofs, hip roofs and flat and low slope gable roofs. The plurality of PV modules170,172,174have short edges with width running in cross-slope direction. Further, the rail-less roof mounting system100has the ability to cantilever the plurality of PV modules170,172,174for both portrait and landscape orientation, for example, 13 inch cantilever portrait and 19 inch cantilever landscape.

The preferred embodiment reduces the number of parts, the size, and the cost of the parts, resulting in a total part count of approximately 151(a 50% reduction) and a total mounting system hardware cost of $0.30/W retail (a 54% reduction). Further, the labor time to install the rail-less roof mounting system100is decreased by a minimum of 35%, which results in the reduction of installation times by over 55% as installation efficiencies grow. When the rail-less roof mounting system100is installed for bridging the plurality of PV modules170,172,174, it is revealed a decrease of around 47% in non-electrical installation hours. Additional system design and procurement soft-costs are reduced by 67%, when utilizing the system.

FIG. 12illustrates one embodiment of a clamp assembly196in accordance with the present invention. The clamp assembly196is small in size and adaptable to use for end-clamping the plurality of PV modules170,172,174. The clamp assembly196includes a clamp member198and a plate member200. The clamp member198includes an aperture (not shown) on an inner surface202thereof and a pair of holes (not shown) to receive a pair of screws204and the plate member200includes a slot (not shown). The plate member200further includes a grooved edge206to accommodate the PV array skirt186. At least one securing means208is inserted through the aperture (not shown) of the clamp member198and the slot (not shown) of the plate member200to engage the clamp member198and the plate member200.

The presently disclosed system is advantageous because it provides the corner-to-corner coupling arrangement, enabling the bridging of corners of the plurality of PV modules170,172,174. The rail-less roof mounting system100provides a single grounding lug for assembling the PV array consisting of 300 PV modules or less. Further, the rail-less roof mounting system100includes the plurality of wire clips163, which are designed to work in multiple locations to minimize wire management issues. The rail-less roof mounting system100allows for more customizability in the PV array shape by allowing the installer to easily work around roof obstructions like vents, skylights, and other roof protrusions This rail-less roof mounting system100provides the ability to increase vertical leveling adjustability, for instance, 3 inch to 5 inch. The rail-less roof mounting system100has the ability to independently remove a single PV module without deconstructing an entire row of the PV array and allow for easy mounting height adjustment after the plurality of PV modules170,172,174are installed. The rail-less roof mounting system100can be easily assembled and disassembled and the components can be laid flat for easy storage and shipping. Furthermore, the rail-less roof mounting system100would require less manpower to install and rework.

The foregoing description of the preferred embodiment of the present invention has been presented for the purpose of illustration and description. It is not intended to be exhaustive or to limit the invention to the precise form disclosed. Many modifications and variations are possible in light of the above teachings. It is intended that the scope of the present invention to not be limited by this detailed description, but by the claims and the equivalents to the claims appended hereto.