SOLAR POWER GENERATION ASSEMBLY WITH INTEGRATED MOUNTING AND WATER MANAGEMENT AND METHOD FOR PROVIDING SAME

A solar power generation assembly includes a first canopy wing positioned at a first predetermined inclination and a second canopy wing positioned at a second predetermined inclination, wherein the first and second canopies form a dual-incline structure and a main gutter is disposed between the first and second canopies. Additionally, at least one mounting rail gutter extends perpendicular to the main gutter and a secondary gutter extends parallel to the main gutter, wherein the secondary gutter directs precipitation to the mounting rail gutter and the mounting rail gutter directs precipitation into the main gutter, wherein the secondary gutter, the mounting rail gutter, and the main gutter are configured to provide both mounting and precipitation management functionality to the solar power generation assembly.

BACKGROUND

1. Field of the Invention

The present disclosure relates to a solar power generation assembly and methods for providing the same.

2. Description of the Related Art

To reduce dependence on fossil fuels (both domestic and imported) and reduce the negative environmental impacts of such fuel emissions, there is a need to increase the distributed power generation base. Similarly, there is a need to maximize the value and productivity of single-use real estate to facilitate such things as mounting for PV or solar modules, shade for cars, shade for outdoor activities and other events and purposes. Complications and limitations associated with rooftop installations make incorporating solar power generation systems in underutilized open spaces one such means of addressing these needs. This will necessitate an increase of the electrical transmission infrastructure.

Conventional support structures for PV power systems are typically designed such that the module arrays are oriented along a single slope plane. Several drawbacks of these structures are limited sight lines from beneath the structures, avalanching of snow and ice from the system, and difficulty of deployment on parking lots that are not ideally geographically oriented.

Many arrangements have been proposed, but in general the currently available support structures for solar power generation do not integrate mounting and water management features. A need exists for protective structures/systems that shelter from snow, rain, and other precipitation. Accordingly, there is a need for an improved solar power generation assembly and methods for providing the same.

SUMMARY

Aspects of the disclosed subject matter relate to a solar power generation assembly and method for providing the same involving an array of solar generation modules on an inclined structure (e.g. single incline structure, dual-incline structure) which can achieve high energy yields over a wide range of azimuths/orientations.

According to embodiments of the disclosed subject matter, a solar power generation assembly includes a first canopy wing positioned at a first predetermined inclination and a second canopy wing positioned at a second predetermined inclination, wherein the first and second canopies form a dual-incline structure and a main gutter is disposed between the first and second canopies. Additionally, at least one mounting rail gutter extends perpendicular to the main gutter and a secondary gutter extends parallel to the main gutter, wherein the secondary gutter directs precipitation to the mounting rail gutter and the mounting rail gutter directs precipitation into the main gutter, wherein the secondary gutter, the mounting rail gutter, and the main gutter are configured to provide both mounting and precipitation management functionality to the solar power generation assembly.

In one embodiment, a solar power generation assembly includes a first support structure, a main gutter extending along a first longitudinal axis, and a first mounting structure extending in a first plane above a ground surface, the first mounting structure being supported above the ground surface by the first support structure, wherein the first mounting structure comprises at least one mounting rail gutter extending perpendicular to the main gutter in the first plane. Additionally, the solar power generation assembly includes a first array includes a plurality of solar modules, the first array being coupled to the first mounting structure, at least one module clip for mounting at least one of the plurality of solar modules on the mounting rail gutter, the module clip being configured for installation from an underside of the solar module, and a secondary gutter extending perpendicular to the main gutter in the first plane, the secondary gutter being positioned between adjacent solar modules of the plurality of solar modules, wherein the secondary gutter directs precipitation to the mounting rail gutter and the mounting rail gutter directs precipitation into the main gutter, wherein the secondary gutter, the mounting rail gutter, and the main gutter are configured to provide both mounting and precipitation management functionality to the solar power generation assembly.

In one embodiment, a method for providing a solar power generation assembly includes providing at least one fastener into a fastener channel at an underside of a mounting rail gutter, wherein the mounting rail gutter extends perpendicular to a main gutter in a first plane; attaching the mounting rail gutter to a first support structure from the underside of the solar power generation assembly, wherein the first support structure supports a first mounting structure extending in the first plane; attaching a secondary gutter to the mounting rail gutter from the underside of the solar power generation assembly, wherein the secondary gutter extends parallel to the main gutter in the first plane; attaching at least one module clip to at least one of a plurality of solar modules configured in a first array, wherein the first array of solar modules is coupled to the first mounting structure; and mounting the first array of solar modules above the mounting rail gutter and the secondary gutter from the underside of the solar power generation assembly with the at least one module clip, wherein the secondary gutter directs precipitation to the mounting rail gutter and the mounting rail gutter directs precipitation into the main gutter, wherein the secondary gutter, the mounting rail gutter, and the main gutter are configured to provide both mounting and water management functionality to the solar power generation assembly.

DETAILED DESCRIPTION

“Comprising.” This term is open-ended. As used in the appended claims, this term does not foreclose additional structure or steps.

“Configured To.” Various units or components may be described or claimed as “configured to” perform a task or tasks. In such contexts, “configured to” is used to connote structure by indicating that the units/components include structure that performs those task or tasks during operation. As such, the unit/component can be said to be configured to perform the task even when the specified unit/component is not currently operational (e.g., is not on/active). Reciting that a unit/circuit/component is “configured to” perform one or more tasks is expressly intended not to invoke 35 U.S.C. § 12, sixth paragraph, for that unit/component.

“First,” “Second,” etc. As used herein, these terms are used as labels for nouns that they precede, and do not imply any type of ordering (e.g., spatial, temporal, logical, etc.). For example, reference to a “first” motor drive does not necessarily imply that this motor drive is the first motor drive in a sequence; instead the term “first” is used to differentiate this motor drive from another motor drive (e.g., a “second” motor drive).

“Coupled”—The following description refers to elements or nodes or features being “coupled” together. As used herein, unless expressly stated otherwise, “coupled” means that one element/node/feature is directly or indirectly joined to (or directly or indirectly communicates with) another element/node/feature, and not necessarily mechanically.

In addition, certain terminology may also be used in the following description for the purpose of reference only, and thus are not intended to be limiting. For example, terms such as “upper,” “lower,” “above,” “below,” “in front of,” and “behind” refer to directions in the drawings to which reference is made. Terms such as “front,” “back,” “rear,” “side,” “outboard,” “inboard,” “leftward,” and “rightward” describe the orientation and/or location of portions of a component, or describe the relative orientation and/or location between components, within a consistent but arbitrary frame of reference which is made clear by reference to the text and the associated drawings describing the component(s) under discussion. Such terminology may include the words specifically mentioned above, derivatives thereof, and words of similar import.

A solar power generation assembly or Building Integrated photovoltaic (BIPV) racking system with integrated mounting and water management features is disclosed herein. Additionally, a method for providing the solar power generation assembly is disclosed. The solar or photovoltaic (PV) racking system can comprise mounting rails which also function as gutters and attachment points for various components like braces, mini gutters, and clips for solar modules or panels. Further, a method for assembling a solar power generation assembly or system from the underside of the assembly is disclosed. Mounting clips can be assembled to PV panels on the ground and allow them to be attached to the mounting rails from beneath the assembly or system.

Reference will now be made in detail to several embodiments of the invention that are illustrated in the accompanying drawings. Wherever possible, same or similar reference numerals are used in the drawings and the description to refer to the same or like parts or steps.

FIG. 1depicts a solar power generation assembly100(which may be referred to as system100) according to one embodiment. In the example, the solar power generation assembly100is provided as a service station, however solar power generation assemblies and systems described herein can be used for any desirable application, for example a carport, a canopy for shade or otherwise, a garage or any other functional and/or aesthetic structure. For ease of description, solar power generation assemblies for use as a service station having a dual-incline canopy are depicted, however numerous other applications are also possible without departing from the scope of this invention.

Solar power generating assembly100can comprise a first support structure105and a first mounting structure111extending in a first plane above a ground surface. The first mounting structure11can be supported above the ground surface by the first support structure105.

In some embodiments, solar power generating assemblies or systems can comprise one or more canopy wings providing for a single or dual-incline structure. Depending on specifications, canopy wings can differ in length, width, and/or angle of inclination. As an illustrative example, solar power generating assembly100comprises one or more support structures105to or on which a canopy wing A101and a canopy wing B102are attached or disposed, directly or indirectly. Canopy wing A101and/or canopy wing B102can be curved or flat. The lengths of the canopy wings may be equal or different and are typically adjusted to improve the energy yield of the of the assembly or system100subject to the location of the installation site, the orientation of the installation, customer preferences, local zoning limitations, structural considerations, the incline angles, and other conditions that may exist at the installation site.

The assembly or system100may or may not be connected to the public electrical grid or may be connected directly to the owner's electrical system or may be used to power elements connected directly to the assembly or system100. Assembly or system100may be located in fueling stations, open areas, parks, sidewalks, parking lots, roadways, sidewalks, parks, campuses, watersheds, reservoirs, canals, gathering places for education and/or entertainment, transportation nodes, and other uses.

Each canopy wing A101or canopy wing B102can comprise and/or be supported by one or more purlins and/or or transverse support beams107. Support structure105can further comprise one or more vertical support columns108and further consist of, be disposed on or supported by foundation piers and/or footings109. In the example ofFIG. 1, three in-plane support columns are provided (a central support beam, a first peripheral support beam at canopy wing101and second peripheral support beam at canopy wing102). However, in other embodiments a single central support beam can be provided, as one of ordinary skill would recognize. Piers and/or footings may be made of concrete or other adequate foundation material subject to local requirements, structural considerations, seismic considerations, and other requirements and preferences.

As depicted in the top down perspective view ofFIG. 2A-2B, each canopy wing A101and canopy wing B102can comprise a mounting structure111to which an array110is attached. Array110can comprise energy producing (photovoltaic or other) modules112and/or non-energy-producing, decorative or “filler” modules or panels (e.g. decorative modules which are transparent or translucent, with or without decorative designs). As depicted inFIG. 2, array110comprises PV modules112(e.g. laminated crystalline silicon solar cells, photovoltaic thin films or any other energy producing material) and filler panels114. PV modules112can comprise an electrical or junction box115and electrical whips113having connectors113′. Photovoltaic elements may be made of monocrystalline silicon, polycrystalline silicon, amorphous silicon, copper-indium-gallium-selenide (CIGS), thin film, or any other photovoltaic technology. The array110may also be a passive or active solar thermal system. The array110may also include lighting or heating elements, solar thermal elements, and may include a wide range of structures including pumps, water storage containers and other elements for water collection and drainage. System100can also include structures for fans, pumps, tubing, elements for cooling such as spray misters, fans, skylights, antennas, cellular repeaters, illuminated panels, phosphorescent or similar panels to provide passive nighttime illumination, and other structures as may be suitable and desired. System100may also include signage, inverters, combiner boxes, sub-combiner boxes, direct current shutoff boxes, junction boxes, acoustical control panels, hydrogen production and/or storage devices. In some embodiments such as depicted inFIGS. 2A and 2B, assembly or system100can comprise decorative elements and/or signage106(for advertising or design purposes).

Some applications may require a substantially watertight assembly or system such that water leaking from the top103of the assembly100to areas underneath104the assembly100are inhibited or prevented. Furthermore, the ability to install the assembly100, mounting structure111and/or array110from underneath may be significantly more advantageous or even required by some applications. Other assemblies and associated assembly methods can necessitate installers to install an array from the top of the assembly which can be unsafe or otherwise undesirable. Disposed between canopy wing A101and canopy wing B102is a main drainage cavity or gutter120through which water, ice, melting snow and other elements can pass. Additional features of the water management approach of assemblies described herein will be described in more detail below.

The array110and mounting structure111of assembly or system100can be provided in any desirable configuration. In the example ofFIGS. 2A and 3A, array110comprises PV modules112arranged in a “portrait” configuration such that the longest dimension of the PV modules112are parallel to central or main gutter120. As another example described herein, PV modules112can be arranged in a “landscape” configuration such that the longest dimension of the PV modules112are perpendicular to central or main gutter120such as depicted inFIG. 2BandFIG. 3B. To display the versatility of the assemblies described herein, both configurations are presented. Unless otherwise specified, the numerical indicators used to refer to components in Figures denoted with “A” (depicting “portrait”-oriented PV modules) are similar to those used to refer to components or features in Figures denoted with “B” (depicting “landscape”-oriented PV modules). As yet another example, PV modules or panels can be substantially square such that a particular orientation is irrelevant and the assembly can be installed accordingly.

As described herein, the solar power generation assemblies can comprise integrated mounting and water management features. Assembly100can comprise a module mounting rail that also functions as a gutter for water drainage. As depicted inFIGS. 4A-4BandFIG. 5, system100comprises an assembly of parts including PV modules112, panels114, a first or mounting rail gutter122, a second or “mini” gutter124, a whip guide128for managing electrical whips113having connectors113′ associated with module112, and a module clip130for connecting modules to mounting rails and/or gutters. Many of these components may be optional or altered depending on desired configuration. An array attachment device132(e.g. a bent angle132aor a purlin clip132b, or any other desirable fastening device) can attach array110to purlin flanges131and/or support structures or beam(s)107. Cable clips can134can function as cable management devices. Various fasteners136(e.g. bolts, screws, washers, nuts, rivets, self-tapping screws, fasteners with or without watertight sealants, etc.) and/or fastening support devices (e.g. bent plate angles138) can fixedly couple the elements of the assembly100together. Many of these components may be optional depending on desired configuration. The above support, mounting, water management and cable management components can be made be of metals (e.g. aluminum), alloys (e.g. steel), plastics, composites or other structurally and functionally appropriate materials.

FIGS. 6A-B,7A-B,8A-B,9A-B,10A-B, and11A-B depict various views of assembly or system100and the related assembly of components shown in4A-B andFIG. 5.FIG. 6A-Bdepict a top-down view of assembly100, whereas7A-B,8A-B,9A-B,10A-B, and11A-B depict side and underside views of assembly100.

In an embodiment, rail gutter122can comprise a cross-sectional profile having one or more open generally-“U” shaped structure so as to allow adjacent solar modules112to attach to the same rail gutter as well as collect and manage water that falls between adjacent modules112and/or leaks through frame117of module112. Secondary gutter124can comprise a cross-sectional profile comprising a plurality of generally-“U” shaped structure as depicted herein.

In addition to the rail gutter122integrating mounting and water management features, the secondary or “mini” gutter124and the clip130provide both mounting and water management functionality. The clip130can elevate or lift modules112above the mounting rail so as to provide clearance between the top of the mounting rail gutter and bottom of the PV module. This clearance allows the secondary or “mini” gutter to be installed between adjacent PV modules in the other axis of the canopy. The secondary or “mini” gutter can thereby catch rain or precipitation falling between adjacent PV modules and a portion of rain falling on a PV module situated in a higher vertical direction.

In one embodiment, the secondary or “mini” gutter can attach above the mounting rail gutter and extend over the top flange of the mounting rail gutter to transfer water into the mounting rail gutter such as depicted inFIG. 11AandFIG. 11B. However, other configurations are also possible. As another example, the secondary or “mini” gutter could attach below the mounting rail gutter and the central or main gutter can be configured to accept water from the secondary or “mini” gutters.

FIG. 12depicts a side view and two cross-sectional views of rail gutter122according to some embodiments. Rail gutter122can be formed of as an aluminum extruded or roll formed part having a length L. As depicted inFIG. 12, rail gutter122can comprise a generally “U”-shaped body portion140between flanges142. Flanges142can comprise holes, slots or openings144configured to accept fasteners136so as to fixedly couple the rail gutter to module clip130and/or PV module112. The body portion140of rail gutter122can comprise an upward projection or fastener channel146forming a cavity148for accepting a fastener at the underside of gutter rail122. The cavity148can be configured to accept a fastener so as to fixedly couple the rail gutter122to array attachment device132(e.g. a bent angle132aor a purlin clip132b).

FIG. 13AandFIG. 13Bshow various views of module clip130according to some embodiments. The clip130comprises a generally “U”-shaped body portion150between flanges152. Flanges152can comprise holes, slots or openings154configured to accept fasteners136so as to fixedly couple the rail gutter122and/or secondary gutter124to PV module112. As depicted, the profile and shape of clip130is configured to inhibit or prevent any surface of the clip130from transferring precipitation out of a water collection area protected by the mounting rail gutter122and/or secondary gutter124. Furthermore, the clip130comprises projections or “drip” edges156to direct precipitation into the rail gutter122and/or secondary gutter124. The projections156can be configured to abut frame117of PV module112. The relative dimensions of clip130can be modified as desired. For example, the clip130depicted inFIG. 13Acomprises vertically offset flanges152so as to couple gutter rail122to PV module112. As another example, the clip130depicted inFIG. 13Bcomprises flanges152without a vertical offset so as to couple secondary gutter124to PV module112.

FIGS. 14A and 14Bdepict secondary or “mini” gutter124according to some embodiments. The secondary gutter124can comprise a fastening or base portion160and a plurality of longitudinally extending ridges or projections162. The longitudinally extending projections162can form drainage channels for directing precipitation. The base portion160can comprise holes, slots or openings164configured to accept fasteners136so as to fixedly couple the secondary gutter124to rail gutter124. Secondary gutter124can be stamped as a single piece or be roll formed. As depicted, projections162of secondary gutter124can be provided as a solid ridge, a hollow projection defined by a void163, or a combination thereof. Furthermore projections162can comprise square or rounded edges. In the exemplary embodiments depicted inFIGS. 14A and 14B, four projections are provided, however any desirable number of projections and associated drainage channels can be provided.

FIG. 15depicts whip guide128according to some embodiments. Whip guide128can function to manage electrical whips113having connectors113′ associated with module112. Whip guide128can comprise a generally “U”-shaped body portion180having holes, slots or openings184configured to accept fasteners136so as to fixedly couple to rail gutter122and/or secondary gutter124.

FIG. 16A, 16B, 17A, 17Bdepict operations for calculating and designing for an appropriate drainable area of system100. For example, a geographic location can be selected (e.g. Hawaii) with a very high precipitation intensity as a baseline for sizing of the main gutter120, mounting rail gutter122and/or secondary gutter124. In the illustrative example, a ten year storm in the selected location (e.g. Hawaii) can produce water volumes of 17.4 inches of water per hour. A calculating operation can comprise inputting a surface area of the panels112,114or array110a length of gutter for a specific system100. A calculating operation can comprise outputting a required or optimal length and width of the main gutter120, mounting rail gutter122and/or secondary gutter124profiles.

Improved methods of assembling or installing a solar power generation assembly with integrated mounting and water management are also described herein.FIG. 18-25depict operations in a method of assembling or installing a solar power generation assembly, in accordance with an embodiment of the present disclosure. One or more of the disclosed operations can be optional and therefore can be omitted without departing from the scope of the invention described herein. The disclosed operations can occur in sequence and furthermore, in any suitable or desirable sequence or order. Additionally, two or more of the disclosed operations can occur simultaneously.

The assembly or system100is particularly advantageous in that it functions in a manner to allow installation from underneath the assembly100or canopy. The assembly100can be installed from below the canopy101,102, for example on scissor lifts or ladders. Installation from the underside is enabled at least in part by the fastener channel146located at the underside of mounting rail gutter122. Fasteners136can be pre-loaded into cavity148of fastener channel146for each mounting rail gutter122while on the ground. Array attachment device132(e.g. a bent angle132aor a purlin clip132b) is configured so as to allow the mounting rail gutter122to be attached to the purlins or support beam(s)107from underneath the assembly100. PV clips130can be installed on to the PV modules112on the ground and then hoisted on top of the mounting rail gutters122from below while portions of the mounting rail gutter122remain accessible from below for connecting fasteners to other components of the system.

A method of assembling a solar power generation assembly can comprise the operation of providing at least one fastener136into a fastener channel146at the underside of said mounting rail gutter122as depicted inFIG. 19. The method can also comprise an operation of attaching at least one module clip130to solar module112as depicted inFIG. 20. The method can further comprise an operation of attaching a mounting rail gutter122to a first support structure107from an underside104of the solar power generation assembly100such as depicted inFIG. 21. The method can also comprise an operation of attaching a secondary gutter124to a mounting rail gutter122from an underside104of solar power generation assembly as depicted inFIG. 23. The method can further comprise an operation of mounting a solar module112above mounting rail gutter122and secondary gutter124from underside104of solar power generation assembly100via module clip130as depicted inFIG. 22-25.