Patent Description:
In the early development of the solar photovoltaic (PV) industry, the dominant cost component of a system was the PV cells. Over time, the cost of PV cells dropped substantially. As a result, the "balance of system" costs are now a large portion of the cost of buying and installing a solar system. The "balance of system" costs include the use of skilled and the cost of other hardware.

Since housing is a durable good with a long lifetime, a PV solar system can be utilized on a given roof installation for a substantial amount of time. Residential roofs are a good target market, as opposed to commercial rooftops, because residential roofs typically have a substantial unused space. Tile roofs are particularly difficult to retrofit with solar PV because drilling holes in tile is difficult and can result in breakage of the tile.

Existing approaches also tend to damage the integrity of the roofs on which they are installed by requiring supports and wiring conduit to pass through the main section of the roof. In addition, existing installation techniques are not designed for serviceability of the PV system or the roof. Many solar installations utilize standoffs that attach to a housing structure by using fasteners that pierce the roof shingles. Flashing and caulk is used to reduce leakage around these breaches in the roof. However, any hole made in the face of a roof, between the apex of the roof down to the lip of the roof by the fascia, which area is over living quarters, reduces the lifespan of the roof and is apt to cause leakage and integrity problems much sooner than if the roof was not breached. For the PV system to be replaced for an upgrade or repair, skilled labor is required to disconnect the high-voltage electrical wiring of the PV system. Moreover, the disassembly of the PV system is time-consuming and painstaking because of the number of standoffs fastened to the building structure and because of the many rails, brackets, and fasteners used to retain the PV solar panels.

<CIT> discloses a method for attaching and fixing a trestle (<NUM>) which supports an energy conversion device (<NUM>) on a roof (<NUM>) of a building (<NUM>) having eave plates (<NUM>). The method comprises an arrangement step and a fixing step. In the arrangement step, the trestle (<NUM>), which is formed by linking two grid-shaped structural members (<NUM>) by means of a roof top ridge metal fitting (<NUM>), is arranged on the roof (<NUM>). In the fixing step, metal fittings (<NUM>) fixed to the eave plates (<NUM>) are linked and fixed to the trestle (<NUM>) by means of wires (<NUM>). The roof top ridge metal fitting (<NUM>) has a predetermined shape so that after the trestle (<NUM>) is arranged on the roof (<NUM>), the roof top ridge metal fitting (<NUM>) can link the grid-shaped structural members (<NUM>) in a state where the roof top ridge metal fitting (<NUM>) is spaced apart from the roof top ridge (<NUM>).

<CIT> discloses a building structure having a roof on which equipment can be mounted, the building structure comprising a support structure for mounting equipment on the roof.

Disclosed in the specification is an apparatus, system, and method of installation for a support structure of roof mounted equipment, specifically solar panels, on a pitched roof. Modules are prefabricated, then lowered onto a roof using a single hole or access point in the roof to connect the module to the building structure, and to couple wiring to electrical loads, either in the house or on the module or to a grid. A hole is utilized at the apex of the roof where the structural impact is minimal and potential damage from any leaks is minimized. The part of the module that drops into the roof space contains the power electronics. The entry hole in the apex is sealed and protected such that water will not penetrate to it. A clamping structure is attached to the part of the frame in the roof space, which either clamps it to the roofing material or to the roof supports. A module may have any number of any size panels, focusing on a cost effective size for transportation and for fitting popular sizes of roof (from the apex to the gutter). On a wide roof, multiple independent units may be installed.

Standoffs are attached to the framing to keep it the desired distance from the roof surface, but do not attach to the roof. Standoffs are made from flexible material to absorb variations in roof materials. The power electronics that converts the unregulated panel power to usable regulated power is attached between the main support pieces in the roof space, since this is beneath the roof, typically in an interior building space such as an attic, which is protected from the elements, and results in a cheaper interior-grade housing (vs. a NEMA <NUM> rated exterior box). The power electronics housing includes a large (extruded) aluminum heat sink that is multi-functionally coupled between the framing uprights for rigidity. After being lowered into place a "clamp beam" is attached to the framing on either or both sides of the framing to attach it to the roof.

Framing components can use steel or aluminum in cross-sections of an L-bar, T-bar, and square or round tube. Standoffs and panel clamps may be made of metal or non-conductive materials, and may be threaded onto the framing and glued/welded rather than using bolts.

Typical roofing structure is composite shingle over plywood and wood rafters, to which the ends of the clamp beam can be attached (if required). If the roof is tile on top of a wood frame (or similar), the clamp beam is attached to the rafters (if flat) or around them (if shaped to do so). The framing and clamp have a bolthole pattern such that it can accommodate different thicknesses of roof, and thus allow secure attachment with only one bolt per clamp beam (attachment of ends being optional). Since roof rafter spacing is normally a fixed size, the spacing between the framing members can be set such that the clamp beams are close to the rafters on both sides for more secure attachment. To save material or fit tighter spaces the clamp beam may be constructed such that it only extends in one direction. The clamp may also include flanges to stop it twisting vs. the frame. Where the roof rafter spacing is significantly larger than the framing width and a single clamp is insufficient, alternative clamp configurations with a longer reach are used. In building structures using a (structural) beam along the apex of the roof, the vertical part of the framing can pass beside it and the weatherproofing plate(s) would be offset as required.

As an alternative or in addition to clamping, a "battery basket" may be hung from the internal end of the framing that will act as ballast as well as providing safe housing for batteries for storing the solar power.

While a single pitch of PV, e.g., facing south on a building, is expected to be the common configuration, another embodiment accommodates multiple different pitches is also envisaged, e.g., where the pitches face east and west on the building and receive similar amounts of sunlight over a day.

Since the structure and PV panels are preassembled, no external wiring/attachment is performed, and thus, the exterior parts of the equipment can be sealed against the elements prior to installation. This allows the use of materials like steel, rather than aluminum, which is cheaper and more weldable. Welding results in better electrical contact if the framing is used to transfer power.

If metal tubing is used for the uprights, (e.g. square pipe) it may double as conduit for wiring. In addition, it may serve as a place to plug in antenna brackets (see below), in which case simple end-caps may be used to seal the tubes that can be "popped" out so that additional framing can be added after initial installation. Note that the lower end of the tube would be exposed below the electronics so that water ingress through the tubes would not leak onto electronics.

Solar panels can be wired in various configurations, where wiring codes allow: the frame may be used as an electrode to reduce costs further. If the two framing members are electrically isolated then they may be used to carry all the power off the roof (one as the positive connection the other as the negative connection). The power electronics can use its mechanical attachment to the framing as its electrical contact, eliminating the need for special connectors. Otherwise, the PV cables will pass through the rain deflection plate via watertight grommet (or similar).

The minimum cost and maximum efficiency implementation uses the framing for power transfer from parallely coupled PV panels managed by maximum power-point tracking (MPPT) electronics on each panel so that the voltage going into the roof space is low (sub 50V is preferable for US wiring codes), and there is redundancy among the panels. Electrically insulative paint on framing parts is sufficient dielectric protection below 50V. In addition, MPPT tracking electronics can be designed to shut off power automatically when it senses an arc fault. Low voltage systems can also use parts designed for automotive systems that are cheaper due to their volume production.

Roof pitches are variable, but the prefabricated unit can be used over a wide range of angles because the load-bearing member extending into the roof space does not have to be vertical. The rain deflector plate, known also as the interface member, can be hinged at its apex to accommodate the different roof pitches, using a fastener hinge pin that can be tightened once the pieces are in place to hold the desired angle, with optional welding of the hinged interface member for security/connectivity. For a two-sided roof with mirror pitches, the same angle will be set for both halves of the interface member. For single pitch roofs that end at an exterior vertical wall, one half of the interface member would be rigidly attached to the panel framing, while the other half is attached to the building structure flexibly, using foam, Silicone sealants, and/or boots for weatherproofing. Another embodiment uses a dual-pitch hinge. Welding may also be used to achieve more reliable connectivity and structural integrity, either prior to shipment to a known roof pitch, or on-site prior to installation for an unknown roof pitch.

If an installation requires extra stability (under strong winds etc.), in examples not part of the present invention, the frame may be tied down using steel wire(s) from attachment points on the lower end of the frame to assemblies at the lower edge of the roof - at or around the gutter, where the main roof area's integrity will not be compromised if holes are drilled (i.e. any leaks caused will be beyond the walls). If the framing runs all the way from the apex to the lower edge of the roof by the gutter, the lower standoffs may be constructed such that they attach to the roof by screws or bolts. Attachment points on the framing used for hoisting the PV assembly onto the roof double as tie-down points - noting that the framing in <FIG> extends beyond the PV panels for that purpose.

The same equipment can be used on mono-pitch roofs or mid-pitch if the rain deflection plate is laid under the upper side shingle or tile.

Residential installation can be accomplished by one to two workers. One person would be on the roof to cut the hole and guide the unit, the second would operate a "cherry picker" to lift the units from a delivery truck to the roof. Hoops, or lift-brackets, can be welded to the framing to aid hoisting the unit. Once in place a technician can finish the installation from within the roof space. If the cherry picker in question can be operated by remote control, then a single person could perform the entire installation if also qualified for internal wiring. Removal of the frame and PV panel for servicing utilizes the reverse process, i.e. no in-place servicing of the PV panel and electronics is required. Instead, the unit is removed and replaced or upgraded.

The PV panels can be sized such that on roofs where multiple units are installed, adjacent units have some small clearance, assuming a unit falls between alternate sets of rafters (for wider panels as shown in <FIG>). The appearance from the ground is then similar to existing systems where panels are abutted (making maximum use of the roof space), but has the advantage that any single unit can be removed for service/replacement.

The standoff design will depend on the roof construction, but for clay/ceramic tiles plates with a foam or rubber that can adjust to the tiles are used so that there are no high pressure points that might cause fracture, and the weight is spread over a number of tiles. The foam/rubber is deeply ribbed so that water can drain through and not collect on the top side.

In simple installations, one would expect the output of the power electronics to be grid-tied AC power. Some additional redundancy can be achieved by wiring the DC side of the inverters in parallel between units so that on the failure of an inverter stage in any unit its power will be transferred to other units, thus avoiding complete loss of the unit. The DC bus created by doing this may be used directly for off-grid power.

Since this framing system is intended to sit at the highest point on a roof, it makes an excellent platform for antennas for line-of-sight networking, and since it is expected to be on a lot of roofs it is particularly suited to use with small cells and mesh networks in the <NUM>-<NUM> range, the availability of solar PV and battery backup power makes it extremely reliable. Electronics for relaying network traffic may be combined with the power electronics for the solar, bridging to networks that will work inside the residence or standard cell phone networks. In particular, this may be used with high bandwidth fiber-optic wiring like that used with a DC bus system to bridge gaps in fiber-optic distribution.

Example embodiments are illustrated by way of example and not limitation in the figures of the accompanying drawings, in which like references indicate similar elements and in which:.

Other features of the present embodiments will be apparent from the accompanying drawings and from the detailed description that follows.

An apparatus and system for a support structure (SS) and a method for mounting (solar) equipment and the support structure onto pitched roofs. In the following description, for the purposes of explanation, numerous specific details are set forth in order to provide a thorough understanding of the various embodiments. It will be evident, however to one skilled in the art that various embodiments may be practiced without these specific details.

Referring now to <FIG>, a front view, top view, and side view of a building structure <NUM>-A having a preassembled support structure and solar panel unit <NUM>-A, also referred to as a pre-assembled module, on a first side <NUM> of a two-sided roof, that pierces the roof <NUM> only at the apex <NUM> is shown, not according to the present invention.

The support structure (SS) <NUM>-A includes at least one support rail <NUM> for supporting the equipment, i.e., solar panels <NUM>, coupled to one or more standoffs <NUM> for maintaining the equipment <NUM> at a distance away from a face <NUM>-A of the roof <NUM>. SS <NUM>-A is preassembled off the roof for install on the roof <NUM> as a single unit. SS <NUM>-A requires no fasteners to penetrate the face <NUM>-A of the roof in order to retain the SS <NUM>-A to the building structure <NUM>-A. SS <NUM>-A does penetrate the roof <NUM> of the building structure, but not on the face <NUM>-A of the roof. Rather, SS <NUM>-A penetrates the roof only at a region <NUM> covered by the ridge shingle <NUM> at apex <NUM> of the roof <NUM>. The one or more standoffs <NUM> have no retention feature to couple them to the roof of the building structure, e.g., no fasteners, holes for fasteners, etc. that would penetrate roof <NUM>. The one or more standoffs <NUM> transmit only a compressive load toward, and not a tensile load away from, the surface of the roof without penetrating the roof. The SS <NUM>-A with solar panels <NUM> is preassembled off the roof for installation on the roof as a modular unit.

The main support (MS) <NUM>-A includes a load-bearing member <NUM>, and an interface member <NUM> has a face that mates with the apex of the roof, i.e., the inverted "V" shape that matches the inverted "V" shape of the apex of the roof. Additionally, interface member <NUM> is larger than the gap, or roof opening, <NUM> through which the LBM passes. Beneficially, the interface member <NUM> provides at least one of a pivot point for any torque loads from the equipment, a physical support of weight load of the equipment <NUM> and balance of support structure <NUM>-A, and a weather shield for the hole in the roof. Only the portion of load-bearing member <NUM> located below interface member <NUM> extends beyond an imaginary plane formed by the interface member <NUM> in order to penetrate through the apex <NUM> of roof <NUM> into interior space <NUM> where SS <NUM>-A will be attached to interior structure <NUM>, i.e., SS <NUM>-A will be attached to rafters in attic. The imaginary plane of the interface member <NUM>, when installed on the building structure <NUM>, is the roof surface <NUM> under each respective side of the interface member <NUM>.

The MS <NUM>-A additionally includes a counterbalance member <NUM>, coupled to the LBM <NUM>, for absorbing torque-loads generated by the equipment, e.g., wind load on solar panels <NUM>. While counterbalance member <NUM> is capable of absorbing all torque loads of module <NUM>-A, the present example, not part of the present invention, also includes a tie-down member <NUM> coupled to at least one support rail <NUM> and has a length that allows the tie-down member to be attached to the building structure <NUM>-A at a location, e.g., overhang <NUM>, that is outside of face <NUM>-A of roof <NUM>, such that face <NUM>-A of roof <NUM> is not penetrated, thereby preserving the waterproof integrity of the face <NUM>-A of roof <NUM>. In one example, not part of the present invention, only a single tie-down <NUM> is required to retain a lower-end of the entire SS <NUM>-A.

While power transmission from solar panels <NUM> is provided by traditional wiring <NUM>-A, as shown in <FIG>, the present example, not part of the present invention, is well-suited to utilizing support rails <NUM> and main support <NUM> to conduct power to inverters, especially if module <NUM>-A is operated at low-voltage, e.g., sub-50V in US, thereby making it a low-risk hazard. In this latter example, the plurality of rails, i.e. first rail <NUM>-A and third rail <NUM>-C (for an additional parallel module only partially shown) are selectively coupled to each other electrically, and to the renewable energy source (solar panels), according to polarity, i.e. positive (+), and are selectively coupled to at least one of the load-bearing members <NUM>-B electrically, according to polarity, (+), in order to conduct current generated by a solar panel <NUM> to the building or to a grid. Similarly, a second rail <NUM>-B is electrically coupled to a second polarity (-) of the renewable energy source, and physically coupled to a second LBM <NUM>-A, which has the same polarity. Rails of one polarity, i.e., <NUM>-A are electrically insulated from rails of a different polarity, i.e., <NUM>-B and -C, both of which are coupled to electrical devices in interior <NUM> of building <NUM>-A to provide isolation required by safety rules, and a less harsh interior setting allowing for less-expensive interior-rated electronics. The ultimate destination of the power is one or more electrical loads of a battery, a device in the building structure, and a grid, e.g., via optional power electronics housing <NUM>-A, -B of <FIG>, where the power can be conditioned and the voltage boosted for DC or AC applications. Connections from solar panels <NUM> and power electronics in housing <NUM>-A to rail <NUM> and LBM <NUM> can be made by welding pieces together, or by connecting support structure components with self-tapping fasteners, that cut a clean metal connection, and using rubber-sealed washers to provide a moisture proof sealing, which reduces corrosion and resistance buildup.

Referring now to <FIG>, a front view of a building <NUM>-D with an alternative single-slope roof architecture is shown having a preassembled support structure <NUM>-D with solar panels <NUM> that pierces the roof only at the apex, not according to the present invention. Since the architecture of preassembled support structure <NUM>-D is a single-slope without a mirror copy of the roof on the opposite side of the apex, there is an overhang <NUM>-D1 on the lower part of roof <NUM> and an overhang <NUM>-D2 on the upper part of roof <NUM>, to which the support structure <NUM>-D can be either tied down or attached without penetrating roof face <NUM>-D, thus preserving roof integrity. Ridge shingles are not present in the present in the baseline roof of the present example, not part of the present invention, but then can be used to cover interface member <NUM>. Consequently, a single preassembled module can still be utilized for installation as a single unit to save time and money in the present example. However, housing for battery and power electronics will use an exterior grade NEMA <NUM> rated exterior box.

Referring now to <FIG>, a front view of a building structure <NUM>-E is shown having a preassembled support structure and solar panel unit <NUM>-E, located on both sides of a two-sided roof <NUM>, <NUM>, which pierces the roof <NUM> only at the apex <NUM>, according to one or more embodiments. The present embodiment provides a more balanced solution, though it is most likely applied to an east-west oriented apex, providing a similar sun exposure on both sides <NUM>, <NUM> of the roof. Optional gusset assembly <NUM> provides improved torque-absorbing capability and balance in the support structure <NUM>-E. Optional battery basket <NUM> coupled to bottom of load-bearing member <NUM>. All three factors of the gusset <NUM>, battery ballast <NUM>, and balanced modules <NUM>-E enable the present configuration to eliminate a tie down of the lowest portion of the module <NUM>-E The main support <NUM>-E absorbs all of a torque load generated by the equipment on the SS in one embodiment. Thus, no tie-down is needed to retain a lower end of the SS <NUM>-E.

Referring now to <FIG>, an oblique view of a preassembled main supports <NUM> is shown with integrated electronics module and battery module, which is installable as a single unit on a roof, according to one or more embodiments. Also shown are rails <NUM> and standoffs <NUM>, coupled to main support <NUM>, for supporting weight of solar panels <NUM> against roof <NUM> as shown in <FIG>. Main support (MS) <NUM> includes two load-bearing members <NUM>, each having a first end, <NUM>-A a second end <NUM>-B, and an interface member <NUM> disposed between first end <NUM>-A and second end <NUM>-B, wherein interface member <NUM> has a face that mates with the apex of the roof, e.g., an inverted "V" and is larger than the gap <NUM> through which the second end <NUM>-B of LBM <NUM>, as shown in <FIG>. MS <NUM> optionally includes a housing <NUM>-A and <NUM>-B, slated for storing at least one of a power electronics for solar panels <NUM>, signal processing electronics for optional transceiver, and a battery, respectively, and coupled to second end <NUM>-B of the LBM <NUM> and disposed below the imaginary plane created by each leg of the inverted "V" of the interface plate <NUM> such that housing <NUM>-A, -B will be located below the roof <NUM> when installed in the building structure, as shown in <FIG>, <FIG>. Housing <NUM>-A includes a battery that provides backup power for an electrical system of the building structure, an optional transceiver, or a power grid. Optional adapter mount <NUM> disposed on first end <NUM>-A of LBM <NUM> is for receiving at least one transceiver, such as that shown in subsequent <FIG>, which will be disposed above apex <NUM> of the roof <NUM> in order to provide a line of sight for transceiving, e.g., in a mesh network.

Rail <NUM> and load bearing member <NUM> can be utilized as a conduit to route power and ground wires <NUM>-A across the roof plane to an interior space <NUM> of building <NUM>, as shown in <FIG>. Similarly, load bearing member <NUM> can be used as a conduit to route power, ground, and data lines <NUM>-B from first end <NUM>-A of LBM <NUM> to an interior space <NUM> of building <NUM>, for access to power electronics and digital signal processing equipment disposed in housing <NUM>-B. Power plug <NUM> can be used for supplement power, e.g., to optional transceiver device <NUM> of <FIG>, if coupled to main support <NUM>.

As an example of the torque absorbing capabilities of main support <NUM>, as applied to a building structure of <FIG>, if a force F1 is exerted on rail <NUM>, such as a wind load during a storm, it creates a torque T1 that tries to lift the lower portion of support structure <NUM>-A off a roof <NUM>. A balancing force F3 is applied to standoffs <NUM> of counterbalance members <NUM> at the roof <NUM> to create a counter-torque T2.

Referring now to <FIG>, a cross-section of a square-tube rail <NUM> is shown for supporting a solar panel in the support structure and for providing a conduit enclosure <NUM> for power and ground wires, according to one or more embodiments. Square-tube rail <NUM> has an internal cavity through which wires may be routed. This reduces installation materials for separate conduit, and labor spent to bend the conduit and affix it to the support structure. Similarly, in <FIG>, an oblique view of an angle-iron rail <NUM> is shown for supporting a solar panel in the support structure, including a conduit enclosure <NUM> for power and ground wires, according to one or more embodiments.

Referring now to <FIG>, a view of a standoff <NUM> for a composite shingle roof is shown, according to one or more embodiments. Standoff includes a flexible face piece <NUM> that interfaces with the composite shingle roof, e.g., roof <NUM> of <FIG>. Face piece can be any weather resistant material that offers elasticity and shock absorption while avoiding adhesion over time to composite shingles. Similarly, <FIG> shows an oblique view of a standoff <NUM> with a wide base <NUM> and silicon pad <NUM> for low unit loading on a tile roof, according to one or more embodiments. A softer silicon material absorbs more loads without transmitting them to the clay roof tile, which may otherwise crack. Silicon pad <NUM> is grooved <NUM> in a downward direction <NUM> of roof, to allow flow of water there through and to provide breathing to avoid adhesion to the tile.

Referring now to <FIG>, an oblique view of a multiple transceiver attachment to the support structure is shown, according to one or more embodiments. Transceiver assembly <NUM> includes any one or more communication protocols, such as a cellular transceiver <NUM> coupled to the adapter mount <NUM> for providing a microcell station for local cellular communications. Another possible transceiver coupleable to the adapter mount of the SS is a high-frequency transceiver <NUM> for providing a short reach relay communication to another high-frequency transceiver in a mesh network in order to transmit data between the microcell stations and an edge router that is coupled to a switching office or server farm. By having transceiver assembly <NUM> located on ubiquitous solar installations, a natural mesh grid is available across a typical urban or suburban neighborhood, which is where bandwidth is in demand for wireless communications.

Referring now to <FIG>, an oblique view of a hinged interface member <NUM>-G is shown, according to one or more embodiments. Hinged interface member <NUM>-G flexibly adjusts the two flanges <NUM>-A and <NUM>-B to match a specific roof pitch within a wide range of possible roof pitches. Hinge pin <NUM> is threaded on one end with a capture bolt to provide a clamping of desired position. Alternatively, hinged interface member <NUM>-G can be welded during preassembly for a known roof pitch or welded in the field for an unknown roof pitch. Cutout <NUM> is oversized to accommodate steep roof pitches that require a longer cutout, as compared to a shallow pitch roof that requires a smaller cutout. A rubber grommet can also be provided around LBM <NUM> to fill any gaps with cutout <NUM> in interface member <NUM>. Pin <NUM> can be threaded through LBM <NUM> to offer further retention of LBM <NUM> on building structure <NUM>-A.

Referring now to <FIG>, a top view of a cascaded PV panel module <NUM> down an extended-height roof is shown, according to one or more examples, not part of the present invention. A typical module <NUM>-A of PV panels <NUM> is similar to that shown in <FIG>. However, in the present example, additional sets of panels <NUM> and <NUM> are coupled serially down a roof of a building structure, with rails <NUM>-A and <NUM>-B coupled to respective rails in subsequent modules via fastening means <NUM>. A serial arrangement as shown would require a tie down on the end of panel set <NUM> furthest from apex <NUM>. This example would require some on-roof assembly due to the length of the module.

Referring now to <FIG>, a side view of a telescoping support rail system <NUM> is shown, according to one or more embodiments. View <NUM> illustrates a closed, or retracted, position of the telescoping rails <NUM>, <NUM>, <NUM> while view <NUM> illustrates an expanded or deployed position of the telescoping rails. <NUM>, <NUM>, <NUM>, with installed solar panels <NUM>, each of which is slightly larger than the one nesting within it. This embodiment allows for more compact storage and shipment of solar systems having more solar panels in a module than provided in <FIG>. Telescoping rails can have a series of holes that allows for some flexibility in length for different roof sizes. Fasteners lock the telescoping rails into their final position for deployment.

Referring now to <FIG>, a side view of a cable-tensioned telescoping support rail system <NUM> is shown, according to one or more embodiments. Cable <NUM> is fixed at end <NUM>, retractable by reel <NUM> for storage and shipment of module <NUM>. Once telescoping rails <NUM>, <NUM>, and <NUM> are extended and fastened to their proper length, a tension can be placed on the assembly via cable <NUM> to ensure rigidity and integrity.

Referring now to <FIG>, a flowchart <NUM> of a method to install and remove a modular PV support structure is shown, according to one or more embodiments. Flowchart <NUM> is described herein as implemented on exemplary support structure <NUM> on building structure <NUM>-A of <FIG>, unless noted otherwise, including the alternative embodiments described herein.

Operations <NUM> through <NUM> provide for installation procedure <NUM>. In operation <NUM>, a support structure <NUM>-A is received for supporting equipment, notably PV solar panels <NUM>, on a roof <NUM> of building structure <NUM>-A. Structural system <NUM>-A is received as a modular unit, e.g., delivered by flatbed truck at the work site, with solar panels <NUM> installed, and optional battery and power electronics housing <NUM>-A and -B of <FIG>, already installed and wired. Sensitive optional equipment, such as transceiver assembly <NUM>, can be installed in situ, on the roof, after support structure <NUM> is secured in order to avoid damage. Because support structure <NUM> is preassembled, including pre-wiring, installation on building <NUM>-A is greatly simplified, thereby saving time and money.

Operation <NUM> requires the creation of an opening in a ridge of a roof to accept the main support of the structural system. The first sub step is to remove the ridge shingles/ tile <NUM> to get access to the wood panel sheets thereunder. On a new house, the plywood base of the roof can be cut short, thereby leaving a gap, or opening, <NUM> at the apex <NUM> of the roof <NUM> to receive the portion, e.g., <NUM>-B end of load-bearing member, of the support structure <NUM> that penetrates the plane of the roof <NUM> to be disposed in the interior space <NUM>, e. g, an attic. Many houses already have this gap <NUM> at the apex <NUM>, for installation of a ridge vent. In this case, the sheet metal or plastic ridge vent can be cut out to create the necessary gap. In operation <NUM>, an optional opening in apex, or ridge, <NUM>, is created to accommodate housings <NUM>-A, -B of <FIG> for the battery and power electronics.

Turning to operation <NUM>, the preassembled modular support structure <NUM> is lowered onto the roof, without upper and lower cross braces <NUM>-B, -A attached. A semi-skilled worker can make the installation single-handedly if she is qualified for low-voltage wiring, and if the boom lift used to raise and lower the support structure <NUM> is remotely operable. Support structure <NUM> is lifted by lift hooks / hoop flanges installed on the support structure, or by a webbed strap under the structure, and the second end <NUM>-B, with associated housings <NUM>-A, -B, is then threaded through the opening <NUM> in apex <NUM> into the interior space <NUM> of building structure <NUM>-A. The support structure is seated when the interface member <NUM> and standoffs <NUM> naturally come to rest against the roof <NUM>. At this point, there is no need to fasten the support structure to the roof to prevent it from sliding down the roof, because the load-bearing member <NUM> is sufficiently strong to retain the base weight of the support structure <NUM>, save a condition of unusually strong winds.

In operation <NUM>, with the boom harness still attached, the installer can secure support structure <NUM> to building structure <NUM> by installing cross-brace <NUM>-A, -B in the interior <NUM> space, either by threaded lug bolts or by clamping mechanism. Because the load-bearing member <NUM> is installed adjacent to the rafter, the interface member <NUM> loads down on the plywood as well as on the rafter, thereby providing structural integrity. An alternative cross brace could capture a bottom-side of a rafter thereby placing the height of the rafter in compression while pulling down on load-bearing member <NUM> in tension, thereby ensuring a preloaded main support <NUM>. Optional tie-downs <NUM> can also be attached in this step, especially for support structures that are lengthy, e.g., more than two panels. For two-panel support structures <NUM>, the cross-bracing and optional counter member.

In operation <NUM>, ridge shingles are installed. The ridge shingle <NUM> is the easiest and least risky shingle to replace on the roof because they are easily replaced, and they do not disturb any adjacent shingles. In fact, a carefully removed ridge shingle can be reused after the support structure is installed, thus guaranteeing shingle color matching and reducing cost. In comparison, replacing shingles midway down a roof if needed in a traditional solar system installation does disturb adjacent shingles, especially those layered over the shingle of interest, with a frequent side effect of leaking.

In operation <NUM>, electrical wiring is coupled, both for the solar panel electrical generation, i.e., <NUM>-A, as well as wires <NUM>-B for transceiver operation. Optional AC building power is provided via outlet <NUM>. Power electronics in housing <NUM>-B can provide maximum power-point tracking (MPPT) on a per-module basis, e.g., for the two solar panels <NUM> shown. Additional modules installed side-by-side on roof <NUM> provides parallel sources of power, each with its own micro-inverter and MPPT module. In this manner, troubleshooting for a failed or underperforming solar system is easily accomplished. Furthermore, if wired in parallel, oversized micro-inverters from a set of solar panels on support structure <NUM> can absorb current from an adjacent set of solar panels that has failed. A serial arrangement of PV solar modules is also usable with the present disclosure.

Operation <NUM> inquires whether a support structure and attached solar panels needs to be serviced or upgraded. As mentioned, with a parallel and per-module electronics system, a failed or underperforming module is easier to detect. If no removal is needed, then the solar system remains operational.

Operations <NUM> through <NUM> provide for removal procedure <NUM>. If a failed module is identified, or is desired for upgrade, then in operation <NUM>, the electrical wiring is decoupled, and in operation <NUM>, the support structure <NUM> is detached from the building <NUM>-A. This step includes removal of the ridge shingles <NUM>, and sensitive equipment, e.g. optional transceiver assembly <NUM>.

In operation <NUM>, support structure <NUM> is raised off roof <NUM>, e.g. by a boom lift, and placed on transportation away from the work site. Presumably, a replacement module is available for installation afterwards, via operations <NUM> to <NUM>. Regardless, ridge shingles that were removed in operation <NUM> are now reinstalled to provide sealing integrity of the roof.

By using method <NUM>, the installation and removal of solar systems is accomplished quickly and efficiently. This has the benefit of proliferating usage of PV and thermal solar usage, with the associated environmental benefits.

While the present disclosure focuses on PV solar modules, the present invention is well suited to any type of equipment mounting, including thermal solar, air-conditioning, etc. Methods and operations described herein can be in different sequences than the exemplary ones described herein, e.g., in a different order. Thus, one or more additional new operations may be inserted within the existing operations or one or more operations may be abbreviated or eliminated, according to a given application, so long as substantially the same function, way and result is obtained.

Although the present embodiments have been described with reference to specific example embodiments, it will be evident that various modifications and changes may be made to these embodiments.

Claim 1:
A system comprising a roof (<NUM>) of a building structure and a support structure (<NUM>-A) for mounting equipment on the roof (<NUM>), the support structure (<NUM>-A) comprising:
at least one support rail (<NUM>), for supporting the equipment;
one or more standoffs (<NUM>), coupled to the at least one support rail, for maintaining the equipment away from the roof (<NUM>); and wherein:
the support structure (<NUM>-A) is preassembled off the roof (<NUM>) for installation on the roof (<NUM>) as a single unit; no tie-down is present to retain a lower end of the support structure (<NUM>-A); and
the support structure (<NUM>-A) penetrates the roof (<NUM>) of the building structure (<NUM>-E) only at an apex of the roof (<NUM>), the support structure further comprising: a main support (<NUM>) comprising: a load-bearing member (<NUM>) having a first end (<NUM>-A), a second end (<NUM>-B), and an interface member (<NUM>) disposed between the first end (<NUM>-A) and the second end (<NUM>-B), wherein the interface member (<NUM>) has a face that mates with an apex of the roof (<NUM>), and wherein the interface member (<NUM>) is larger than a hole or a gap in the apex of the roof (<NUM>) through which the second end (<NUM>-B) of the load-bearing member (<NUM>) passes; the interface member (<NUM>) provides at least one of a pivot point for any torque loads from the equipment, a physical support of a weight load of the equipment, and a weather shield for the gap in the apex; and only the second end of the load-bearing member (<NUM>) extends beyond an imaginary plane formed by the interface member (<NUM>) in order to penetrate the apex of the roof (<NUM>) on which the support structure is installed.