Solar shade structure

A shade structure assembly includes at least one column member. A horizontal beam is secured at a top end of the column member. A first rail is secured to a first end and a second rail is secured to a second end of each horizontal beam. At least one truss assembly is secured to the rails. The truss assembly includes at least two truss members arranged in spaced parallel relation. Structural supports connect the truss members along two of the truss beams and panel supports connect the truss members along two of the truss beams. The panel supports mount a panel array. Each truss member may comprise a center truss portion and one or both of a first and second truss extension. Each truss member may be comprised of a universal center truss portion and one or both of a first and second truss extension.

FIELD OF THE INVENTION

The present invention relates to a shade structure, and more particularly to a shade structure incorporating solar photovoltaic modules, and still more particularly to a shade structure for use in a parking lot or as a seating area for pedestrians.

BACKGROUND OF THE INVENTION

Solar shade structures in use today typically provide shade and electricity generation. However, the current state of the art of construction of such structures, misses the opportunity to pre-engineer and pre-fabricate and as a result each solar shade structure is typically custom identified, engineered, and fabricated on-site. Whether a large or small installation of solar canopy structures, the typical process identifies the length, width, and height of each canopy in a sales proposal for each potential parking lot and pedestrian area, then those same solar canopy structures are evaluated by a licensed engineer for structural code conformance and submitted to the authority having jurisdiction (AHJ) for a building permit. Once the design is approved by the AHJ, the structural components must be custom shop fabricated, assembled, and erected on-site for a complete installation. And furthermore the electrical system design of each solar canopy structure must be individually evaluated for electrical code conformance and good solar energy production. Once the design process is complete and the construction process begins, the typical solar shade structures do not incorporate pre-fabricated assemblies and instead each solar shade structure is custom built on-site with individual structural members. These individual structural members are often the only pre-fabricated elements of current solar canopy structures. For example the typical supporting steel purlins and beams are fabricated to precisely work for the specific solar canopy structure length, width, and height having a quantity of solar photovoltaic modules with a specific length, width, and height having no additional dimensional tolerance for different configurations or module sizes. The resulting cost of the design process and capital investment in the solar canopy structures yields a substantial financial barrier to property owners for installing such solar canopy structures. In addition such solar canopy structures typically are permanently installed in such a manner so as to make disassembly, relocation, and reuse virtually impossible. Again the permanent installed nature of such solar canopy structures in parking lots and pedestrian areas creates a disincentive for property owners who must maintain flexibility of land use for the purpose of constructing permanent enclosed structures (buildings).

The invention proposes to standardize design of solar canopies/shade structures, as well as, the structural and electrical engineering of the solar shade structures owing to the fact that discrete building blocks can be pre-engineered, pre-fabricated, and pre-approved to meet regulatory/code standards. To further elaborate, the potential solar and shade benefits, as well as, costs of the solar shade structures can be quickly quantified and understood through the use of pre-designed discrete building blocks overlaid onto satellite photographs or other planning mechanisms. During the design and engineering phase, the use of pre-designed discrete building blocks can flexibly adapt to individual site characteristics and constraints with various planning layouts. Once energy outputs and costs are established, a customer can then approve a set of design documents and obtain AHJ approval. This task is made much quicker and easier through the use of pre-designed and pre-engineered standard solar shade structure assembly elements. Pre-engineered standard solar shade structure assembly elements can be pre-fabricated, transported to the project site, constructed and installed while accommodating and adapting to the individual site characteristics and constraints without need of re-engineering and re-work. Post installation, these same standard solar shade structure assembly elements can be disassembled, relocated, and reused in the event there is a land use change or change in purpose requiring the removal of the solar shade structures.

The invention incorporates a variety of foundation assemblies to provide a range of solutions including permanent in-ground foundations, as well as, temporary above grade relocatable mass that resists wind uplift, seismic, gravity and other such structural forces. The invention can adapt to various application and site requirements by allowing the incorporation of in-ground structures such as columns and concrete piers and/or above grade mass such as shipping containers or similar. The capability of having standard foundation options is a further embodiment of the building block concept offered by the invention.

Currently there are commercial solutions that provide structures which deliver temporary power generation, or, temporary shade/shelter in an emergency situation, natural disaster, or similar event. The subject invention incorporates building blocks that can provide energy generation, energy storage, and shade in a single structure that can be easily assembled and disassembled. In addition the temporary power solution can assist with energy needs in non-emergency settings in order to support microgrids or similar community oriented electric utilities while also offering shade to further promote community focused gathering space.

Accordingly there is a need for a system which uses pre-fabricated standardized sub-structures that can be used as building blocks to assemble a final solar shade structure on-site and that can be selectively removed and/or upgraded to accommodate future advancements. The present invention fills these, as well as other, needs.

SUMMARY OF THE INVENTION

Briefly described, a shade structure assembly includes at least one column member arranged vertically with respect to the ground. When two or more column members are used, the members are spaced in parallel relation to one another. A respective horizontal beam is perpendicularly secured at a top end of the column member. Each respective horizontal beam has opposing first and second ends and a pair of rails is arranged in spaced parallel relation to one another. A first rail of the pair of rails is secured to the first end of each respective horizontal beam and a second rail of the pair of rails is secured to the second end of each respective horizontal beam. At least one truss assembly is secured to the pair of rails. The at least one truss assembly includes at least two truss members arranged in spaced parallel relation to one another. Each truss member comprises three or more truss beams. A plurality of structural supports connects the at least two truss members along two of the truss beams and a plurality of panel supports connect the truss members along two of the truss beams. The panel supports may also be used to mount a panel array thereon. Each truss member may also comprise three truss beams arranged to form an irregular triangle.

In accordance with a further aspect of the present invention, a shade structure assembly includes at least one column member arranged vertically with respect to the ground. When two or more column members are used, the members are spaced in parallel relation to one another. A respective horizontal beam is secured at a top end of the column member. Each respective horizontal beam has opposing first and second ends and a pair of rails is arranged in spaced parallel relation to one another with a first rail of the pair of rails secured to the first end of each respective horizontal beam and a second rail of the pair of rails secured to the second end of each respective horizontal beam. At least one truss assembly is secured to the pair of rails. The at least one truss assembly includes at least two truss members arranged in spaced parallel relation to one another. Each truss member comprises three or more truss beams. A plurality of structural supports connects the truss members along two of the truss beams and a plurality of panel supports connects truss members along two of the truss beams. A panel array is mounted to the panel supports. The panel array may include one of more photovoltaic panel members. Each truss member may also comprise three truss beams arranged to form an irregular triangle.

DESCRIPTION OF ENABLING EMBODIMENTS

With reference toFIGS. 1 and 2, there is shown an embodiment of a modular shade structure assembly100in accordance with an aspect of the present invention. Assembly100generally comprises one or more column members112arranged vertically with respect to the ground. Column member112may be secured directly within the ground, such as via a post hole filled with concrete or, more preferably, anchored to a concrete footing114(FIG. 2) as is known in the art. Optionally, column member112amay be a provided as an above-grade mass shipping container or the like, that is not secured directly within the ground, making the structure readily disassemble-able for use in temporary installations. Preferably, portable column member112awould be selected to adequately resist wind uplift, seismic, gravity and other potential forces imposed on the structure.

Perpendicularly mounted at the top end116of column member112/112ais a horizontal beam118having first and second ends120,122. A pair of rails124,126is arranged in spaced parallel relation to one another with first rail124secured to first end120of each horizontal beam118, while second rail126is secured to second end122of each horizontal beam118. Column member112/112a, horizontal beam118and rails124,126(along with footing114, when included) form a standardized mounting substructure127. A plurality of truss assemblies128may then be mounted along rails124,126. Truss assemblies128are configured to mount a plurality of panel arrays130thereon. Without limitation thereto, each panel array130may include one or more photovoltaic (PV) panels131. Other possible panel compositions include metal roofing and glass/plastic panels having a range of visual and optical qualities from opaque, to translucent, to transparent, with and without custom colors or designs.

As shown inFIGS. 4A-4Eand as will be discussed in greater detail below, truss assemblies128may be configured and oriented in a number of ways so as to be selectively mountable onto a common mounting substructure127depending upon such things as size and space considerations, the cardinal orientation of the installed shade structure assembly100, and other practical and/or aesthetic considerations. It should be noted that, while four truss assemblies128are shown inFIGS. 1 and 2, any number of truss assemblies may be used as desired or as determined by structure assembly length or on-site demands. Additionally, a gap129may be located between adjacent panel arrays130. The size of gap129may be variable according to the site where the solar shade structure is built. In this manner, gap129may provide flexibility to adjust the total length of shade structure assembly100, as well as provide for easy removal of one or more panel arrays130or individual PV modules for maintenance, replacement or upgrade. Additional, provision of gap129may allow truss assemblies128to be mounted in different orientations with respect to each other during installation.

With additional reference toFIG. 3, each truss assembly128may include two or more truss members132arranged in spaced parallel relation to one another. As exemplified inFIGS. 4A-4E, and discussed in greater detail below, each truss member132may be comprised of three or more truss beams134and may include additional bracing members136a,136b,136c. Turning again toFIG. 3, a plurality of structural supports138may connect adjacent truss members132along respective adjacent truss beams134. Additionally, a plurality of panel supports140may connect truss members132along two of truss beams134. Structural supports138may also form a horizontal or sloped screen panel assembly that creates a tray139for hiding and securing electrical wiring and equipment used in conjunction with the PV modules of panel arrays130. Tray139may also allow electrical wiring and equipment to be located in an easily identifiable space such that maintenance servicing may be more efficient.

Referring again toFIGS. 1 and 2, in accordance with another aspect of the present invention, shade structure assembly100may also include one or more screen panels141,143arranged about column member112. Opposing screen panels141,143may create a space145there between that may be used to hide and secure electrical components the PV modules of panel arrays130, such as DC/AC inverters, electrical disconnects, and electrical junction boxes. As with tray139formed by structural supports138, screen panels141,143may allow for more efficient maintenance servicing.

FIGS. 4A through 4Eshow non-limiting examples of various truss assembly configurations with differing structural support/panel support orientations that may be constructed using a center truss portion and a first and/or second truss extension as discussed below.FIGS. 4A and 4Bmay be suitable for shading a double row of cars as shown generally inFIGS. 1, 2 and 8(assemblies100′). In accordance with an aspect of the present invention, the truss assemblies may be modular constructions which may be fabricated off-site and delivered en masse to the installation location. To that end, a template truss assembly128aand128b(FIGS. 4A and 4B) may be arranged to define three distinct zones133a,133band133ccomprised of a universal truss unit133b′ and a first and second truss extension units133a′,133c′. As shown, three truss beams134a,134b,134cmay be arranged to form an irregular triangle which comprises zones133a,133band133c. As shown inFIGS. 4C through 4E, one or more of truss beams134a,134b,134cmay be omitted or truncated to form an irregular polygon which may further include a truss beam134dor134ecomprised of a universal truss unit133b′ and a first or second truss extension units133a,133c′.

Once again, the truss assembly embodiments shown inFIGS. 4A-4Eare only examples and, in no way, are meant to limit the invention. However, as further discussed below, the embodiments provided inFIGS. 4A-4Eoffer a distinct advantage by providing commonality in truss construction. Turning toFIGS. 10A-10C, in a standard fixture for constructing truss assembly128aor128b, by simply eliminating section135(FIG. 10B) or section137(FIG. 10C) from truss assembly128aor128b, respectively, truss assemblies128cor truss assemblies128d/128emay be formed on the same fixture.

In a further aspect of the present invention, the truss assemblies128a-128emay comprise a universal truss unit133b′ comprising zone133band may include a first member134c′, a second member134a′, a first side member136aand a second side member136b. As can be seen inFIGS. 4A-4E, universal truss unit133b′ defines a quadrilateral structure wherein a plane P1defined by first member134c′ is disposed at an acute angle A1relative to a plane P2defined by second member134a′. First truss extension unit133a′ is configured to extend outwardly from first side member136a. First truss extension unit133a′ includes first extender portion134c″ which extends collinear with first member134c′ and second extender portion134a″ which extends collinear with the second member134a′. Second truss extension unit133c′ is configured to extend outwardly from second side member136b. Second truss extension unit133c′ includes third extender portion134c′″ which extends collinear with first member134c′ and fourth extender portion134bwhich is configured to form an obtuse angle with second member134a′. As can be seen by truss assemblies128a-128e, a truss assembly includes the universal truss unit133b′ and any combination of one, none or both of the first truss extension unit133a′ and the second truss extension unit133c′. Additional profiles may be selected by inverting which of first member134c′ and second member134a′ is configured to mount to the underlying support structure (i.e., compare truss assembly128a(FIG. 4A) with truss assembly128b(FIG. 4B) and truss assembly128d(FIG. 4D) with truss assembly128e(FIG. 4E)).

Turning once again toFIGS. 4A-4E, truss assembly128a(as shown inFIG. 4A) may be suitable for structure assemblies100/100′ arranged in a North/South orientation with truss beam134alying along horizontal plane H. At least a portion142of truss beam134awithin zone133bis configured to mount to rails124,126as described above. The remaining portion144of truss beam134a(zone133a) includes a plurality of structural supports138secured thereon. Truss beam134b(zone133c) lies at an angle with respect to horizontal plane H and includes a plurality of structural supports138secured thereon. Truss beam134cextends across zones133a,133b,133cand interconnects truss beam134aat South end146and truss beam134bat North end148. As a result, truss beam134cis oriented at an angle relative to horizontal plane H such that North end148is disposed above South end146when truss assembly128ais secured to mounting substructure127(seeFIG. 1). Being so arranged, truss assembly128amay maximize sun exposure at photovoltaic panel arrays130mounted on panel supports140(see alsoFIGS. 1 and 2).

As shown inFIG. 4B, truss assembly128bis equivalent to truss128aflipped 180° about its horizontal axis. Truss assembly128bmay be suitable for structure assemblies100/100′ arranged in an East/West orientation, with truss beam134clying along horizontal plane H. At least a portion150of truss beam134cwithin zone133bis configured to mount to rails124,126as described above. The remaining portions152,154of truss beam134cin zones133a,133cinclude a plurality of structural supports138secured thereon. Truss beams134aand134beach lie at a different angle with respect to horizontal plane H with truss beam134aextending across zones133a,133bwith truss beam134bcovering zone133c. Truss beam134cinterconnects truss beam134aat West end156and truss beam134bat East end158. As a result, truss beam134ais oriented at an angle relative to horizontal plane H such that West end156is exposed to sun to a greater degree/extent that East end158. Being so arranged, truss assembly128bmay maximize sun exposure at photovoltaic panel arrays130mounted on panel supports140.

FIGS. 4C, 4D and 4Eshow truss assemblies128c,128d,128e, respectively, which may be suitable for shading a single row of cars, such as along the boundary of a parking lot (see, e.g., assembly100″ inFIGS. 5, 6 and 8). Truss assemblies128cand128dmay be suitable for structure assemblies100″ arranged in a North/South orientation while truss assemblies128emay be suitable for structure assemblies100″ arranged in an East/West orientation. As described above with respect to truss assemblies128a,128b, the lower surface(s) of truss assemblies128c,128d,128emay include a plurality of structural supports138secured thereon while the upper surface(s) of truss assemblies128c,128d,128emay include plurality of panel supports140. Each truss assembly128c,128d,128emay then be arranged to maximize sun exposure to photovoltaic panel arrays130mounted on panel supports140.

While both truss assemblies128c,128dare configured for North/South orientation, these assemblies comprise different structures due to the mounting of each truss assembly128c,128don mounting substructure127within zone133bof the truss assembly. Thus, as shown inFIG. 4C, for those structure assemblies100″ having vehicles parked to the south of zone133b(south of mounting substructure127), zone133ais included and truss beam134bis omitted. Truss beam134cis truncated such that truss beam134cis connected to truss beam134avia truss beam134dso as to remove zone133cfrom truss assembly128c. Alternatively, as shown inFIG. 4D, for those structure assemblies100″ having vehicles parked to the north of zone133b(north of mounting substructure127), zone133cis included while zone133ais removed. Accordingly, truss beam134bis included and truss beams134a,134care truncated. Truncated truss beam134cand truss beam134beach lie at a different angle with respect to horizontal plane H. Truncated truss beam134cinterconnects truss beam134bat North end156dand truss beam134econnects truncated truss beams134a,134calong South face158dso as to remove zone133afrom truss assembly128d.

For those structure assemblies100″ having vehicles parked in an East/West orientation, at least a portion150eof truss beam134cis configured to mount to rails124,126as described above. The remaining portion154eof truss beam134cincludes a plurality of structural supports138secured thereon. Truncated truss beam134aand truss beam134beach lie at a different angle with respect to horizontal plane H. Truss beam134cinterconnects truss beam134bat West end156eand truss beam134econnects truss beam134awith truss beam134calong East face158eso as to remove zone133afrom truss assembly128e.

Turning now toFIG. 7, there is shown an embodiment of a modular shade structure assembly100ain accordance with another aspect of the present invention. Modular shade structure assembly110ais similar with respect to modular shade structure assembly100described above, but is configured to accommodate both vehicular and bicycle parking. As bicycles are shorter than a vehicle, additional structures160may be located about column members112while still providing shade to either side of the column members. Additional structures160may be prefabricated units having dimensions chosen by the property owner or based upon available space/geography of the assembly location. Structures160may accommodate, without limitation thereto, solar/electrical equipment required by modular shade structure assembly100aand/or commuter or consumer conveniences, such as parking meter payment kiosks, automatic teller machines (ATMS), vending machines, electric vehicle charging stations and the like. Electrical power for these conveniences may be supplied by the photovoltaic panel arrays130mounted on modular shade structure assembly100a.

As shown inFIG. 9, modular shade structure assemblies100,100amay be used to cover a parking lot161that is graded to have a sloping surface162. A series of modular shade structure assemblies100,100amay be mounted adjacent one another with a space164therebetween. As a result, parking lot161may be covered by modular shade structure assemblies100,100ato provide shade while also allowing water run-off and drainage. As further shown inFIG. 9, modular shade structure assemblies100,100amay accommodate one or more free-standing commuter or consumer conveniences166(such as parking meter payment kiosks, automated teller machines (ATMS), vending machines, electric vehicle charging stations and the like, as discussed above) within the space located between column members112and/or vertical screen141,143(see alsoFIGS. 1 and 2). Modular shade structure assemblies100,100amay also contain pedestrian seating elements (not shown) and truss assemblies128may include lighting fixtures (not shown) as part of the structure.

From the above discussion, those skilled in the art will appreciate the many advantages offered by the modular shade structure assemblies of the present invention. By way of example and without limitation thereto, the shade structure assemblies of the present invention may be configured to cover a pre-determined number of standard vehicular parking spaces without creating significant projections into the vehicular drive aisles, thereby alleviating or eliminating possible additional building and zoning requirements as well as the potential of accidental impact damage from passing vehicles to the structures or other vehicles. Moreover, the shade structure assemblies of the present invention may be comprised of one or more substructures that can be assembled, on-site, in a planned way taking into account such things as the geometry of the environment with respect to solar radiation, the orientation and shape of the surface, such as a parking lot, and functional realities such as electrical power lines, entry-rights-of-way, pedestrian cross-walks, etc. In this manner, one or more components of the shade structure assemblies may be assembled in a factory setting and/or on the ground adjacent to the project site then moved into position, such as via a crane. This may allow for decreased on-site installation time which minimizes construction time and disruption to the owner of the parking lot. Additionally, the shade structure assemblies may also be embodied as a kit containing pre-manufactured structural components such as foundation/footing elements, column members, beams and rails, truss assemblies, PV modules, and/or commuter or consumer conveniences and the like.